Characteristics of Air-Side Particulate Fouling Materials in Finned-Tube Heat Exchangers of Air Conditioners

Fabrication and Characterization of Superhydrophobic Al-Based Surface Used for Finned-Tube Heat Exchangers

Enhancing the heat transfer performance of heat exchangers is one of the main methods to reduce energy consumption and carbon emissions in heating, ventilation, air-conditioning and refrigeration (HVAC&R) systems. Wettability modified surfaces developed gradually may help. This study aims to improve the performance of heat exchangers from the perspective of component materials. The facile and cost-effective fabrication method of superhydrophobic Al-based finned-tube heat exchangers with acid etching and stearic acid self-assembly was proposed and optimized in this study, so that the modified Al fins could achieve stronger wettability and durability. The effect of process parameters on the wettability of the Al fins was by response surface methodology (RSM) and variance analysis. Then, the modified fins were characterized by field-emission scanning electron microscopy (FE-SEM), 3D topography profiler, X-ray photoelectron spectroscopy (XPS), and Fourier transform infrared spectroscopy (FTIR), respectively. The durability of the superhydrophobic fins was investigated by air exposure, corrosion resistance, and mechanical robustness experiments. The RSM and variance analysis demonstrated that a water contact angle (WCA) of 166.9° can be obtained with the etching time in 2 mol/L HCl solution of 10.5 min, the self-assembly time in the stearic acid ethanol solution of 48 h, and drying under 73.0 °C. The surface morphology showed suitable micro-nano structures with a mean roughness (Ra) of 467.58 nm and a maximum peak-to-valley vertical distance (Rt) of 4.095 μm. The chemical component demonstrated the self-assembly of an alkyl chain. The WCAs declined slightly in durability experiments, which showed the feasibility of the superhydrophobic heat exchangers under actual conditions.

Particle loading rates for HVAC filters, heat exchangers, and ducts

The rate at which airborne particulate matter deposits onto heating, ventilation, and air-conditioning (HVAC) components is important from both indoor air quality (IAQ) and energy perspectives. This modeling study predicts size-resolved particle mass loading rates for residential and commercial filters, heat exchangers (i.e. coils), and supply and return ducts. A parametric analysis evaluated the impact of different outdoor particle distributions, indoor emission sources, HVAC airflows, filtration efficiencies, coils, and duct system complexities. The median predicted residential and commercial loading rates were 2.97 and 130 g/m(2) month for the filter loading rates, 0.756 and 4.35 g/m(2) month for the coil loading rates, 0.0051 and 1.00 g/month for the supply duct loading rates, and 0.262 g/month for the commercial return duct loading rates. Loading rates are more dependent on outdoor particle distributions, indoor sources, HVAC operation strategy, and filtration than other considered parameters. The results presented herein, once validated, can be used to estimate filter changing and coil cleaning schedules, energy implications of filter and coil loading, and IAQ impacts associated with deposited particles.

PRACTICAL IMPLICATIONS

The results in this paper suggest important factors that lead to particle deposition on HVAC components in residential and commercial buildings. This knowledge informs the development and comparison of control strategies to limit particle deposition. The predicted mass loading rates allow for the assessment of pressure drop and indoor air quality consequences that result from particle mass loading onto HVAC system components.