Concept of Integrating Air Conditioning System with Thermoelectric Units and Double-Pipe Heat Exchanger for Efficient Waste Heat Utilization: An Experimental study B. Manoj, U.C. Arunachala, H.S. Arunkumar International Journal of Refrigeration, 2026 • The thermoelectric generator’s suitability for air-conditioning is demonstrated • Refrigerant temperature dominates power generation over flow rate • Both refrigerant temperature and flow rate are crucial for heat recovery • Heat transfer augmentation techniques influence condenser length In the vapor compression air conditioning system, a notable amount of heat dissipation is obvious. The condenser plays a critical role in maintaining the refrigerant phase prior to the expansion valve. Previous studies have primarily focused on recovering waste heat through conventional thermal routes. However, in automobiles and other allied fields, in addition to process heat, direct energy conversion techniques are also in practice. Hence, the present experimental study is an attempt to demonstrate the implementation of both electrical and thermal routes to extract waste heat to the maximum possible extent from the air conditioning system. For this exercise, Coolselector software was used to fetch the operating conditions, (including tonnages of 1.5 TR, 3.0 TR, and 4.5 TR) and later, the entire operations were simulated. The thermoelectric generator (TEG) array produced a decent level of electrical power with negligible drop in process fluid temperature. In the double pipe heat exchanger (DPHX), the secondary side could extract a good amount of heat. Hence to identify the best-case, exergy analysis was done separately for the TEG and the DPHX, in that the 3.0 TR case identified as the best. Further, to enhance system performance, inserts were used in the DPHX, resulting in 26% and 46% improvement in effectiveness for louvered tape and twisted tape configurations, respectively. Even condenser length optimization was carried out to understand the influence of various heat transfer augmentation techniques. Though this approach is still in the pre-mature stage, appropriate design of condensers, heat spreaders, and heat exchangers can yield remarkable results.
Integration of open natural circulation system to single-phase immersion cooling of data centre: an experimental approach for proof of concept B. Manoj, U. C. Arunachala, K. Varun International Journal of Sustainable Engineering, 2026 Cooling systems are the second-largest energy consumers in data centres, ensuring safe operating temperatures for high-heat-flux electronics. Among various thermal management techniques, immersion cooling is highly efficient but requires significant infrastructure investment due to its active cooling mode. To address this limitation, a proof of concept is demonstrated, integrating an open-loop natural circulation system with single-phase immersion cooling. Novel concepts are introduced based on data centre load patterns, achieving a power usage effectiveness close to unity. While data centres are often connected to waste heat recovery systems, this experimental study (using simulated heating) validates the efficiency of a completely sustainable and maintenance-free mechanism. However, the proposed concept can also be integrated with external heat recovery systems. Without active heat removal, immersion cooling alone allowed the heater surface temperature to rise from approximately 35 °C to 70 °C within 54, 43, and 22 minutes for heat loads of 500 W, 750 W, and 1000 W respectively. With the proposed system, the temperatures remained below 60 °C, 65 °C, and 70 °C, even after 120 minutes. Additionally, the introduction of novel floating fins resulted in temperature drops of 4 °C, 5 °C, and 8 °C for the respective wattages compared to the base models. At a later stage, transitioning from a fully passive mechanism to a hybrid approach yielded notable results, particularly at lower heat loads, as air injection into hot legs enhanced the natural circulation flow rate due to void buoyancy. Since this study uses a simulated setup (immersion heater), future work can implement this proof of concept using a realistic heat source.
Insights on the instability and stabilizing techniques for natural circulation loops P.K. Vijayan, Swati Gangwar, Dev Banitia, U.C. Arunachala, S. Nakul, D.N. Elton, K. Varun Nuclear Engineering and Design, 2025 There is a generally held belief that the insertion of an orifice which is equivalent to increasing the L t /D ratio is always stabilizing SPNCSs. In this paper, it has been shown that the insertion of an orifice can stabilize or destabilize depending on whether the loop is operating near the lower or upper threshold of instability for single-phase loops. Besides, increasing the L t /D ratio increases the unstable zone in single-phase loops and, hence, is destabilizing. For two-phase loops, insertion of an orifice or increasing the L t /D ratio significantly shrinks the stable zone increasing the unstable zone as in single-phase loops. Thus for both single-phase and two-phase loops, reducing the L t /D is stabilizing. Contrary to this, for the supercritical loops L t /D ratio (or orificing) has a complex effect on instability. For example, increasing the L t /D or insertion of an orifice shrinks the unstable zone giving a stabilizing effect. Also, reducing the L t /D ratio is seen to shift both the lower and upper thresholds to higher powers and, in this sense, is stabilizing. However, it is also found to widen the unstable zone with a decrease in L t /D and, in this sense, is destabilizing. The paper also reviews the available stabilizing techniques to identify the techniques which do not significantly reduce the heat transport capability while stabilizing. For single-phase and two-phase loops, the best way to stabilize is the reduction of L t /D ratio as it stabilizes with enhancement in heat transport capability. Introduction of an orifice enhances the unstable zone in single-phase and two-phase loops whereas it has a mixed effect in supercritical loops. Increase in L t /D is found to reduce the flow and hence narrows down the pseudocritical region and hence the unstable region to stabilize supercritical loops. Reduction of L t /D ratio is found to stabilize supercritical loops at high inlet temperatures, whereas it widens the unstable region at low inlet temperatures, which is attributed to the widening of the pseudocritical region. The paper also examines the various requirements for maximizing the power of natural circulation based reactors. Apart from reducing the frictional force, enhancing the surface area density in the core has a significant influence on enhancing the reactor power and various options for the same has been identified in the paper.
A comprehensive review on the effect of turbulence promoters on heat transfer augmentation of solar air heater and the evaluation of thermo-hydraulic performance using metaheuristic optimization algorithms G. K. Pramod, U. C. Arunachala, N. Madhwesh, M. S. Manjunath Environment Development and Sustainability, 2025 Solar air heaters are characterized by poor thermal performance due to limited heat transfer capability of air, thereby necessitating the need for design modifications. Among a different system performance augmentation technique, turbulence promotors are widely used owing to its effectiveness. Based on design parameters such as geometry, size, pitch and arrangement of turbulence promoters, varying levels of heat transfer increment with the pressure drop penalty is achievable. This led to the development of new designs which could offer on optimum thermo-hydraulic performance for a wide range of Reynolds number. Such research invariably requires a thorough insight of data related to various design parameters and optimal thermal–hydraulic performance range. This article provides a detailed overview of various turbulence promotor designs and their optimal thermal–hydraulic performance ranges compiled from a wide spectrum of experimental and numerical studies. Apart from outlining the general flow characteristics of each turbulator design, this study also evaluates different metaheuristic optimization algorithm such as bonobo optimization (BO), particle swarm optimization and teaching–learning-based optimization algorithm for enhancing the thermal–hydraulic performance parameter (THPP). The study shows that the BO algorithm does not exhibit local trapping due to its self-adapting nature of the optimized parameters which makes it a promising choice for THPP optimization studies in air heater applications. The extensive review also shows that the arrangement pattern of rib turbulator plays a key role in thermo-hydraulic performance augmentation. Based on the BO optimization analysis, the range of THPP is determined for the optimized geometry of turbulence promoters. In the pool of rib design, transverse prism rib, multi-V-rib, multi-V-shaped rib with staggered rib, sinewave-shaped rib with gap and S-shaped ribs exhibits an optimal THPP range of 2.05–3.32, 2.43–2.94, 3.00–3.61, 1.58–3.40 and 2.05–3.74, respectively. Other turbulence promotor designs such as winglet vortex generator, dimple protrusion in arc shape and multi-V-baffles exhibits optimal THPP range of 1.95–2.2, 2.44–3.68 and 1.75–2.01, respectively. At the end, the study proposes key research gaps such as the use of combined ribs and vortex generators and discrete fin arrays of different geometry as future scope of research. Graphical abstract
Effective thermal management of photovoltaic modules equipped with innovative concentrating techniques M. Kiran, U. C. Arunachala, K. Varun International Journal of Sustainable Engineering, 2025 Due to growing apprehension about energy density in Photovoltaics (PV), researchers have proposed multiple concentrators and thermal-management techniques. In the present study, based on system operation and power output, two designs are proposed: compound parabolic collector (CPC) based PV (PV-CPC) and Fresnel lens-based PV (PV-FNL). A gravity-assisted evaporative cooling system in PV-CPC resulted in 7.1 ℃ to 11.2 ℃ temperature drop, which led to 13.1% to 26.1% improvement in power output. A higher fill factor (0.72 compared to 0.65 for reference model) also complements the system design, which had minimum tracking. Further, owing to both electrical and thermal outputs, the PV-FNL model is suggested, which had an effective forced cooling. Significant improvement in module power output (46% to 59%) followed by useful heat gain (500 W with water exit temperature as ≈ 95 ℃) upholds the efficacy of the proposed system. However, the low fill factor (0.49) indicates an additional cooling requirement. Though the results are promising, enviroeconomic and life cycle analysis of PV-CPC and PV-FNL is worth gauging for in-field applications. Even, in PV-FNL configuration, the multi-junction cell-based module and CPC integrated thermal receiver can fetch better and more reliable results.
Numerical and experimental investigations of thermohydraulic performance enhancement of triangular duct solar air heaters using circular wing vortex generators G. K. Pramod, N. Madhwesh, U. C. Arunachala, M. S. Manjunath Heat Transfer, 2025 This study presents the thermohydraulic performance enhancement in a triangular duct solar air heater (TSAH) using circular wing vortex generators (CWVGs) on the absorber plate using computational fluid dynamics (CFD) methodology for the Reynolds number (Re) range of 6000–21,000. The use of wing vortex generators offers relatively lower interference with the core flow region, while the circular geometry offers a smooth curved edge, which reduces multiple vortex interactions in the wake region, thereby limiting the pressure drop. This study explores the impact of flow attack angle, longitudinal pitch, transverse pitch, and diameter of CWVG on the thermohydraulic performance of TSAH. The results reveal that a lower flow attack angle exhibits enhanced heat transfer with a lower friction factor penalty. The nondimensional diameter greater than d/Dh = 0.325 tends to limit heat transfer and exhibits an increased friction factor. The transverse pitch parameter also exhibits a similar trend where the threshold nondimensional pitch is found to be 1.5. The highest improvement in Nu is 4.37 times that of smooth duct for d/Dh = 0.433, Pl/d = 1, Pt/d = 1.5 and α = 20° at Re = 6000. The highest rise in friction factor is about 10.23 times that of smooth duct for d/Dh = 0.433, Pl/d = 1.0, Pt/d = 1.5, and α = 20° at Re = 21,000. The highest thermohydraulic performance parameter (THPP) value is about 2.23 at Re = 6000, with THPP values ranging from 1.69 to 2.23 across different CWVG configurations. Finally, mathematical correlations are developed for Nu and friction factors which are in close agreement with CFD results, with deviations averaging 5.03% and 3.69%, respectively.
Optimizing the geometry of tube-in-tube Thermosyphon heat transport device from instability Perspective: A computational study K. Varun, U.C. Arunachala, P.K. Vijayan Applied Thermal Engineering, 2024 • Thermosyphon heat transport device – a compact natural circulation loop. • Applications – passive decay heat removal in nuclear power plants. • Flow instability in the form of recirculation loops. • The center-line elevation difference beyond 0.8 m eliminates instability. • Increasing area ratio beyond 1.75 leads to instability. • Irrespective of geometry, all instabilities vanish at higher heater powers. Since the Fukushima disaster, there has been a significant surge in the adoption of infinite time passive decay heat removal systems. In this context, the thermosyphon heat transport device (THTD) has distinct advantages over natural circulation loops (NCLs). Previous studies proved that the THTD experiences flow instability characterized by recirculating loops under specific geometric and operational conditions. However, identifying the critical value for these parameters remains unresolved. Therefore, the present study deals with the geometric optimization of THTD through computational (CFD) simulations. Initially, the CFD model is validated with earlier experimental data, which resulted in a minimal deviation of −2 % to 5 %. The parameters for geometric optimization of THTD are height of the system (H), the center-line elevation difference between the source and the sink (Δ z ), heater length ( L h ), cooler length ( L c ), hot leg length ( L hl ), and area ratio (AR) between hot leg and cold leg, under the heater power range of 100 W to 1000 W. The impact of these geometric and operational variations on flow instability is evaluated by observing the presence of recirculation loops, which are identified by analyzing velocity vectors and contours. The key findings of the present study are: flow instability in the form of a single recirculating loop sweeping radially along the cross-section of the annulus, thereby leading to radial flow maldistribution; a center-line elevation greater than 0.8 m eliminates the flow instabilities; interchanging heating and cooling lengths for a given center-line elevation doesn’t alter the criteria for instability; Heater power of 100 W leads to instability irrespective of center-line elevation; the optimal cooling length can be considered as 5 % to 25 % of the total height of the THTD, whereas the optimal hot leg length can be considered as 25 % to 45 % of the total height; and the HTF flow rate increases with a rise in the area ratio until AR=2, after which a flow anomaly occurs, rendering the system unstable. In addition to these aspects, this study also suggests optimal geometric features of THTD to reduce instability and attain perfect unidirectional flow. By integrating findings from current research and past studies, the design methodology for conventional THTD is comprehensively presented to the scientific community.
An open-loop and closed loop based passive thermal management techniques applicable to photovoltaic systems Kiran, U.C. Arunachala, K. Varun Renewable Energy, 2024 Photovoltaic (PV) technology adoption in recent years has experienced significant growth due to its inherent advantages over alternative technologies. Nevertheless, there is a concern regarding performance deterioration due to high operating temperatures. Various thermal management methods have been studied to address this issue, each having its own advantages and disadvantages. Hence, a comprehensive review aimed at developing effective passive cooling techniques was undertaken and two techniques were finalized for outdoor testing viz. natural circulation loop based cooling (PV-NCL) and evaporative cooling (PV-EVP). Though the former version could drop module temperature by 7.4 °C–13.9 °C (Power output increment in the range of 3.5 %–6.7 %), this improvement was not sustained throughout the day due to factors such as flow resistance within the loop and a lack of convective cooling in the vicinity of the cooler. Subsequent experiments confirmed that loop resistance played a dominant role in this phenomenon. Additionally, concerns about water circulation in PV-NCL were resolved through a comparison with water duct-integrated PV. On the other hand, the innovative gravity-assisted water flow for evaporation method (PV-EVP) yielded more promising results, with a power output enhancement ranging from 3.7 % to 11.5 %. However, considering the in-field operational issues, PV-NCL with a modified design will likely be the best technique. • Efficient passive cooling techniques for photovoltaic modules. • A novel application of natural circulation loop in PV thermal management. • Dominance of natural circulation flow over still water cooling. • Evaporative method of cooling with negligible water consumption.
Single-phase thermosyphon heat transport device, a future prospect for heat removal applications: An experimental comparison with heat pipe and two-phase closed thermosyphon H. Eshwar, U.C. Arunachala, K. Varun International Journal of Thermal Sciences, 2024 Over the years, the passive mode of heat transportation has gained immense popularity, which includes two-phase devices viz. Heat pipe (HP) and Two-phase closed thermosyphon (TPCT). But recently, the thermosyphon heat transport device (THTD) entered the pool, wherein the heat transfer fluid (HTF) in liquid phase transports heat by natural circulation (thermosyphon). Hence, to gauge their efficacy, in the present experimental investigation, the three devices (with the same geometry and HTF) are compared by imposing isothermal (40°C–90 °C) and isoflux (50–900 W) heating conditions. In isothermal mode, HP transports heat with a minimal temperature gradient compared to TPCT and THTD. The thermal resistance (TR) of TPCT and THTD is 5.4 to 10.1 times and 6.6 to 10.1 times respectively greater than HP. For isothermal temperatures below 80 °C, the TR of THTD is less than TPCT (viscous limit). Later the trend reverses as the TPCT outperforms, while THTD experiences HTF boiling. Further, the heat extracted by HP is 2.1 to 3.9 times and 3 to 3.5 times greater than TPCT and THTD respectively. Hence, its application is justified if cost is not a concern, while THTD (with high-temperature HTF) is suggested over TPCT on an economic basis. Even the isoflux mode showed a similar trend of TR. The system response (based on time constant) depicted both HP and TPCT have similar and nearly constant values over the heat load range, while in THTD, it decreases with an increase in heat load and approaches the other two. Hence, a high-temperature HTF would lead to competitive results. Further, concerning the heat transport distance, as the TR of THTD remained the same compared to the increment in TPCT, the application of the former is justified in long-distance heat transportation. Ultimately, HP is the front-runner, while TPCT and THTD perform on par depending on operating conditions and geometry.
Status, Trends and Significance of Single Phase, Single and Coupled Natural Circulation Loops in Sustainable Energy Technologies – A Comprehensive Review International Journal of Renewable Energy Research, 2021