Theoretical and Experimental Methodology for the Improvement of EGR-Coolers Design

A. Melgar; A. Horrillo; G. Cabaco; C. Castaño; J. A. Grande

doi:10.4271/2004-01-0052

2004-03-08

Theoretical and Experimental Methodology for the Improvement of EGR-Coolers Design 2004-01-0052

With the aim of accomplishing pollutant emissions policies, EGR-cooler has acquired an important role inside the whole EGR system in diesel engines. This paper presents a methodology to design and size EGR-coolers based on the integration of fluid-dynamic tools (CFD), specifically developed codes, experimental tools and a knowledge bank with previous experiences.

Each different geometry of EGR-coolers (cooler family) requires an initial study through CFD, which allows the characterization of different thermo-fluid-dynamic variables. After that, correlations, related to heat exchange and pressure drop for the cooler family, are obtained from the CFD results and implemented in a fast-running one-dimensional code. This code lets size EGR-coolers with specific design characteristics and performance requirements of this family. An experimental tool carries out efficiency and pressure drop tests on EGR-cooler prototypes in order to validate the theoretical results. In each step, generated data feed the knowledge bank to be used as base in future EGR-Coolers designs.

Finally, an application example for a family of coolers with a determinate morphology of corrugate tubes is presented to illustrate the methodology.

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Theoretical and Experimental Methodology for the Improvement of EGR-Coolers Design 2004-01-0052

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