CFD Optimization of an EGR Cooler for Heavy-Duty Diesel Engines

Lucien Charnay; Hans-Erik Ångström; Lena Andersson; Björn Palm; Lars Östling

doi:10.4271/2001-01-1755

2001-05-14

CFD Optimization of an EGR Cooler for Heavy-Duty Diesel Engines 2001-01-1755

The gas flow and heat transfer in an EGR cooler has been studied using Computational Fluid Dynamics method (CFD). The shell-and-tube cooler is intended for heavy-duty diesel engines EGR cooling applications.

The influence of the diffuser shape has been studied with regards to pressure drop, flow distribution across the tube bundle, and heat transfer. Inlet temperature is 250 °C, and flows varies from 100 up to 200 g/s. These results were compared to experimental measurements. The influence of the bundle size and design has also been investigated for two designs.

A single tube cooler test bench has also been developed to validate the CFD flow and heat transfer models. In flow temperature measurements are provided.

The bigger tube bundle has advantages both in terms of pressure drop and even flow distribution. The mean outlet gas temperature is also decreased by 6% in this case.

The design of the diffuser has important consequences on flow distribution and pressure drop. A smooth “trumpet” form helps obtaining good results in terms of pressure drop compared to rougher design. However, this is obtained at the price of a less even flow distribution, which impairs the heat transfer potential.

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CFD Optimization of an EGR Cooler for Heavy-Duty Diesel Engines 2001-01-1755

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