High-fidelity modeling and optimization of conjugate heat transfer in arrays of heated cables

Following the development of modeling of heat transfer in two-phase flows [1], we have developed a new high-fidelity conjugate heat transfer capability that enables the design of effective cooling techniques in multi-solid/multi-fluid systems. We first verified and validated our model with analytical and experimental results. Subsequently, we used the new methodology to study heat transfer around power cables carrying high currents. We first considered an array of cables with staggered arrangement. Our direct numerical simulation (DNS) results demonstrated that the naturally convected flow leads to a strong horizontal traveling wave in between the cable rows. The strength of the traveling wave, however, is strongly non-uniform in different cable rows, resulting in a significant temperature difference of cables at different rows with the temperature of the cable carrying current of I = 1000 Amp above 90°C. We then considered a configuration with many more cables (120) but carrying lower current of I = 80 Amp. Using different cooling conditions around the box of cables, we found that the maximum temperature never exceeds 50°C. These two different configurations provide possible effective solutions for the design and optimization of the thermal cooling of cables in the 95MW All-Electric-Ship.