Evaluation of a cost-effective galinstan immersion heater design for high-temperature applications

Abstract

This study examines a cost-effective immersion heater design using galinstan as the working fluid in high-temperature conditions, aiming to minimize galinstan volume while maintaining efficient heat transfer. Galinstan, a liquid metal with excellent thermal properties, is advantageous for high-temperature applications but poses challenges due to its high cost. A novel tube-type immersion heater design is introduced, reducing galinstan usage by approximately 50 % compared to conventional shell-type designs. Computational fluid dynamics (CFD) simulations analyze temperature distribution, flow behavior, and pressure drop under upward and downward flow conditions. Results show that upward flow ensures uniform fluid distribution and temperature consistency across varying flow rates, with deviations remaining within practical limits. In contrast, downward flow exhibits significant localized overheating at low flow rates due to buoyancy effects, which are mitigated at higher flow rates. This research offers valuable insights into optimizin immersion heater designs for improved economic and thermal efficiency in industrial applications.