Numerical Analysis of Heat Transfer Process and Mechanisms for High-Temperature Air Flowing Across Staggered Lined Fine Tubes

This study investigates the flow and heat transfer mechanisms of high-temperature air flowing across staggered lined fine tubes in a SABRE-type precooler. Large-Eddy Simulation (LES) was employed to model three-dimensional unsteady flow under constant-property and variable-property air models at inlet temperatures of 400–800 K. The results show that increasing temperature substantially enhances vorticity, turbulent kinetic energy, heat flux, and Nusselt number, while flow separation and pressure drop are intensified. However, when temperature-dependent air properties are incorporated, the wake width increases and the separated shear layers become thicker, while the turbulence/unsteadiness intensity decreases. Consequently, the near-wall shear is reduced and the heat transfer coefficients are lower. Compared with variable-property predictions, constant-property models overestimate the average Nusselt number by 20–40% and the local pressure drop by 40–65%, and they underestimate the air-side temperature drop along the tube rows. These findings demonstrate that real-gas effects significantly alter both aerodynamic resistance and thermal performance. Overall, accurate representation of temperature-dependent air properties is essential for the reliable design, evaluation, and optimization of micro-tube precoolers.