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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

A Novel Approach for Bounding the Stress Experienced by the Core of Utility-Scale Printed Circuit Heat Exchangers Under Thermohydraulic Loads

Printed circuit heat exchangers (PCHEs) have rapidly gained popularity since being introduced nearly three decades ago, and they are currently widely deployed in the petrochemical and aviation industry. Their compactness, thermohydraulic efficiency, inherent suitability for high temperature/pressure fluids containment, and demonstrated durability are some of the reasons the nuclear industry is seeking to adopt this technology as well. However, the relatively strict nuclear-related regulatory design code, especially when classified as critical to the safety of the reactors, is posing challenges to adopting the technology. From stress analysis point of view, one undesirable feature of PCHEs is their geometrical complexity, which is implied by their multilength-scale features. As a result, a full-scale model of a utility-scale exchanger cannot simply be solved on a computer because meshing such components results in a vast number of degrees-of-freedom. Here, this work seeks to address the challenge of stress analyses to PCHEs by presenting a method to simplify the geometry of PCHE designs. The models proposed by this work can be practically analyzed on a standard computer and provide a path for implementing ASME design rules. The analyses presented herein are divided into five separate investigations. Each is carried out to incrementally simplify the analyzed model by addressing features such as the shapes of the flow passages, the complex distribution of stress in large components, the three-dimensionality of the stress and strain, the thermal stresses caused by thermohydraulic operation observed experimentally and more.

42 ENGINEERING↗
DOE OSTI2024

Bypass heat exchanger configuration to reroute core flow

A turbine engine assembly includes a heat exchanger that is in thermal communication with an exhaust gas flow. A bypass passage is provided that is configured to selectively route at least a portion of the exhaust gas flow around the heat exchanger in response to a predefined engine operating condition.

Terwilliger, Neil↗
DOE OSTI2024

On the Corrosion Response of Novel Heat Exchangers Manufactured by Casting of Al-Ce-Mg Alloy

Developing low-cost and durable heat exchangers is critical for next-generation heating, ventilation, air conditioning, and refrigeration systems. The emerging requirement to minimize the total refrigerant charge inventory while ensuring a uniform distribution of refrigerant has led to the deployment of advanced manufacturing strategies. At the same time, corrosion is a longstanding issue for metal components, especially those used in heat exchanger (HX) applications. In this study, Al-Ce-Mg alloy-based HXs have been investigated. The corrosion resistance of HXs prototype manufactured by the casting process has been examined and the potential of a new manufacturing approach has been explored to meet the requirements of emerging needs.

Brechtl, Jamieson↗
DOE OSTI2026

Machine learning based prediction of airflow maldistribution in air-to-refrigerant heat exchangers

Flow maldistribution is a common challenge in heat exchanger (HX) design and particularly important for air-to-refrigerant geometries where capacity losses can approach 65%. This has a major impact on central air conditioning systems, as compact duct design motivates the use of A-type HXs which are known to be affected by airflow maldistribution. Because velocity profiles are difficult to predict, components are often oversized leading to increased material cost, system footprint, and refrigerant charge. Several studies detail airflow maldistribution for individual HXs and packages, but findings cannot always be extrapolated to new designs. In this work, a machine learning (ML) based flow profile prediction framework is developed and applied to two common package configurations: (i) A-type and (ii) U-type HXs, across a broad range of HX geometries and flow rates. Porous media CFD simulations are validated against independent data for both package types as well as comprehensive in house measurements for a finless geometry with shape optimized non-round tubes, which validates the framework for new heat transfer surfaces. The ML models are trained on the porous media CFD simulations, predicting volumetric flow rate (VFR) within 1.1% and 1.9% with maximum relative L 2 norm errors of 0.48 and 0.65, respectively, while also delivering 10 5 speed up factor compared to full porous media CFD. HX level simulations show an up to 9% reduction in heat transfer from flow maldistribution, with greater losses occurring at smaller half apex angles. This framework enables rapid and highly accurate prediction of airflow maldistribution induced capacity degradation.

42 ENGINEERING↗
DOE OSTI2024

Comparative Analysis of Heat Exchangers for High Temperature High Pressure Helium Component Testing

Helium gas loops have been designed and built to gain a better understanding of the gas thermohydraulic phenomena that take place in a helium system. Some of these loops are used for validation and testing of components for high temperature gas-cooled reactors (HTGRs). However, most of them operate at lower pressure and temperature than an HTGR. While these loops can provide valuable information about gas-cooled reactor components, the operating envelope of the experiment is constrained by the maximum operating conditions of the helium loop. In response to the lack of an experimental facility that can provide the infrastructure needed to validate and test components at nominal pressures and temperatures of HTGRS, the HElium Component Testing Out-of-pile Research (HECTOR) facility was designed at Idaho National Laboratory with the assistance of University of Idaho and Walsh Engineering. With the capability to test at temperatures up to 800°C and pressures of 8MPa, HECTOR serves as a critical tool for the advancement of HTGR technology. The facility's primary role is to provide a controlled, high-fidelity environment for the assessment of component resilience and efficiency under nominal HTGR conditions. In the quest to enhance the efficiency and performance of HECTOR, a comparative analysis of three distinct types of heat exchangers—shell and tube, offset strip fin, and printed-circuit—was conducted, focusing primarily on two critical metrics: the required surface area and pressure drop characteristics. The shell and tube heat exchanger, renowned for its robust design and widespread industrial application, was evaluated against the offset strip fin and the cuttingedge printed-circuit heat exchangers, both of which are lauded for their compactness and thermal effectiveness. This comparative study aims to provide detailed insights into the thermal management capabilities of each heat exchanger type under the conditions inherent to HECTOR, thereby facilitating an informed selection for systems demanding high operational integrity and efficiency.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

A signal compensation based cascaded PI control for an industrial heat exchange system

Since the characteristics of the industrial heat exchange system (HES) are drastically affected by variations of the steam pressure, ambient temperature and water quality, it is difficult for the classical cascade PI control system to meet the desirable control objectives. Therefore, in this paper, a deterministic linear model with unmodeled dynamics is used to describe the dynamic characteristics of the HES. It should be noted that the unmodeled dynamics at the previously sampled instant can be calculated using actual measurements and that the tracking error, which includes effects of the rate of changes of unmodeled dynamics on the controlled model, can be accurately determined. An additional compensating signal is obtained with the feedforward control together with a one-step optimal control law. Consequently, the cascade PI control strategy with the signal compensation is established. Furthermore, the simulation and industrial application show that the proposed method can effectively improve the performance of the cascade PI control system, especially when the unmodeled dynamics is subjected to unknown variations.

42 ENGINEERING↗
DOE OSTI2021

Experimental Investigation of Melting and Solidification Processes of Phase Change Material Heat Exchanger

Rapid development and validation of PCM embedded heat exchangers (PCM-HX) concepts warrant a purpose-built test bench. This paper describes a test facility built for testing various PCM-HX configurations and phase change temperatures that will serve to validate the performance of novel PCM-HX designs. The entire test rig is placed in a temperature-controlled environmental chamber. Inside the PCM-HX containers, up to 48 T-type thermocouples can be spatially distributed on and around the tubes depending on the HX type to capture the phase change process over time. In this paper, a straight tube embedded in PCM having a phase change temperature of 37°C in cylindrical containers is tested. The PCM-HX uses water as an in-tube working fluid. Based on the measured data, the energy balance is analyzed, and its temperature distribution is presented. Here, the maximum deviation between the predicted stored energy and the energy stored calculated from experimental measurements is less than 5%.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Circulating fluidized bed connected to a desublimating heat exchanger

Condensable vapors such as carbon dioxide are separated from light gases in a process stream. The systems and methods employ a circulating fluidized particle bed cooled by an out-bed heat exchanger to desublimate the solid form of condensable vapors from the process stream. Gas and solids may be sorted in a separator, and the solids may then be subcooled in a heat exchanger. The condensable vapors may be condensed on the bed particles or in the heat exchanger while the light gases from the process stream, which are not condensed, form a separated light-gas stream.

Baxter, Larry↗
DOE OSTI2021

On-Line Lead/Water Heat Exchanger Sensor/System Feasibility: CRADA 462 [Abstract Only]

The purpose of this project is to develop and demonstrate the feasibility of a high-temperature sensor for on-line structural health monitoring (OLSHM) of the novel heat exchanger tubes in the Hydromine lead cooled reactor. The high temperature sensor takes advantage of the Hydromine heat exchanger tube design that has a relatively cool inlet temperature (~ 350 °C) and the tube ends are in an Argon gas blanket rather than being submerged in a corrosive fluid and the tube ends are conveniently accessible from the periphery of the heat exchanger shell.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

G-Function Library for Modeling Vertical Bore Ground Heat Exchanger

This library contains g-functions (thermal response functions) for standard, regularly spaced vertical borehole ground heat exchangers. In total, it contains 34, 321 configurations. To permit interpolation, each configuration has g-functions for heights of 24, 48, 96, 192, and 384 m. All the g-functions were calculated with burial depths of 2m, and borehole diameters of 15 to 17.5 cm, depending on height. In configurations with uniform spacing, the spacing between the boreholes is set to 5m, though it can be scaled to other horizontal spacings.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Preliminary Plan to Inform Testing of a Heat Exchanger Test Article

This report presents a preliminary plan to guide the qualification testing of advanced heat exchanger (HX) components for nuclear-to-industrial heat transfer applications. The objective is to establish a defensible, physics-based methodology that integrates computational modeling, targeted experimentation, and in-service inspection considerations to demonstrate component performance and reliability under representative reactor conditions. The analysis identifies Sodium-cooled Fast Reactor (SFR) and High-Temperature Gas-cooled Reactor (HTGR) systems as reference configurations in terms of temperature, pressure, and chemical environment. Within these operating envelopes, dominant degradation mechanisms— including creep–fatigue interaction, flow-induced vibration, corrosion, and diffusion-bond deterioration—were evaluated to define test requirements. A comprehensive computationalexperimental framework is proposed to support life prediction and qualification activities. The framework couples high-fidelity structural-mechanics, thermal-hydraulic, and fluid-structure interaction models with accelerated degradation testing to produce a traceable linkage between microstructural evolution, mechanical performance, and remaining useful life (RUL). The approach adheres to established Verification, Validation, and Uncertainty Quantification (VVUQ) standards (ASME V&V 10/20; NUREG-2152) and incorporates a digital-twin architecture for continuous model refinement through data assimilation. The plan further outlines testing methodologies, including pre-test analyses, test-loop design parameters, and sensor placement strategies that maximize information yield while maintaining mechanistic fidelity. Complementary sections describe in-service inspection (ISI), on-line monitoring (OLM), and structural-health-monitoring (SHM) techniques applicable to compact HX geometries typical of advanced reactors. Collectively, these activities establish the technical foundation for demonstrating 40-60-year equivalent service life of advanced heat exchangers in support of the U.S. Department of Energy’s Advanced Reactor and Integrated Energy Systems programs. The forthcoming phase will execute the defined pre-test analyses, initiate hardware fabrication, and implement the integrated testing campaign to validate the proposed qualification methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Modeling of Supercritical CO2 Shell-and-Tube Heat Exchangers Under Extreme Conditions. Part I: Correlation Development

Abstract High-temperature supercritical CO2 Brayton cycles are promising possibilities for future stationary power generation and hybrid electric propulsion applications. Heat exchangers are critical components in supercritical CO2 thermal cycles and require accurate correlations and comprehensive performance modeling under extreme temperatures and pressures. In this paper (Part I), new Colburn and friction factor correlations are developed to quantify shell-side heat transfer and friction characteristics of flow within heat exchangers in the shell-and-tube configuration. Using experimental and computational fluid dynamics (CFD) data sets from existing literature, multivariate regression analysis is conducted to achieve correlations that capture the effect of multiple critical geometric parameters. These correlations offer superior accuracy and versatility as compared to previous studies and predict the thermohydraulic performance of about 90% of the existing experimental and CFD data within ±15%. Supplementary thermohydraulic performance data are acquired from CFD simulations with supercritical CO2 as working fluid to validate the developed correlations and demonstrate its capability to be applied to supercrtical CO2 heat exchangers.

Engineering↗
DOE OSTI2024

A Microchannel Heat Exchanger Produced From a Metal Matrix Composite by Hybrid Laser Powder Bed Fusion and Inkjet Printing

Abstract This paper explores the production of an oxide dispersion strengthened (ODS) 304L stainless steel microchannel heat exchanger (HX) using a hybrid additive manufacturing process of laser powder bed fusion and inkjet printing. The study investigates the capabilities and economics of the hybrid inkjet-laser powder bed fusion (LPBF) process and evaluates the dimensional accuracy, functionality, and mechanical properties of the resulting ODS alloy. The effectiveness and pressure drop of the ODS heat exchangers produced by the hybrid LPBF tool are also determined. Results show that the inkjet-doped samples have a lower mean channel height with higher standard deviation than samples produced by LPBF alone. This is attributed to greater absorption of laser energy for the powder coated with the oxide precursor. The economic analysis shows that the hybrid process has a potential for reducing the unit cost of the heat exchanger based on cost modeling assumptions.

Engineering↗
DOE OSTI2025

Compact Counter Flow Fluidized Bed Heat Exchanger (Final Report)

Generation 3 concentrating solar power systems which utilize solid granular media as the heat transfer and storage media hold promise in reducing the levelized cost of electricity relative to generation 2 systems which utilize molten salt. The particles can be heated to temperatures exceeding 800 °C which enables the use of high efficiency supercritical CO 2 Brayton power cycles. A key challenge associate with the use of solid media is its low bulk thermal conductivity which limits the ability to transfer heat from the particles to a working fluid, such as supercritical CO 2 . Tradition shell and tube and shell and plate heat exchangers feature gravity driven particle flow which limits the maximum particle side heat transfer coefficient in these systems to approximately 400 W/m 2 K. A fluidized bed heat exchanger does not rely solely on gravity for particle flow. Instead, enhanced mixing and horizontal conveyance is achieved through fluidization induced through air injection at the bottom of a bed of particles. A tube bundle within the bed conveys the supercritical CO 2 which is heated via the turbulent particle motion at the tube wall.

14 SOLAR ENERGY↗
DOE OSTI2024

Multi-Material Topology Optimization for High Performance Heat Exchangers

This award allowed RTX Technology Research Center to demonstrate several key objectives related to the design and manufacture of additive heat exchangers. The focus of the project was on creating a multi-physics, multi-material topology optimization tool, then using it to create an ultra-compact, optimized, fully additive heat exchanger.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

A Scalable Compact Additively Manufactured Molten Salt to Supercritical Carbon Dioxide Heat Exchanger for Solar Thermal Application

Design of an additively manufactured molten salt (MS) to supercritical carbon dioxide (sCO 2 ) primary heat exchanger (PHE) for solar thermal power generation is presented. The PHE is designed to handle temperatures up to 720 °C on the MS side and an internal pressure of 200 bar on the sCO 2 side. In the core, MS flows through a three-dimensional periodic lattice network, while sCO 2 flows within pin arrays. The design includes integrated sCO 2 headers located within the MS flow, allowing for a counterflow design of the PHE. The sCO 2 headers are configured to enable uniform flow distribution into each sCO 2 plate while withstanding an internal pressure of 200 bar and minimizing obstruction to the flow of MS around it. The structural integrity of the design is verified on additively manufactured (AM) 316 stainless steel sub-scale specimens. An experimentally validated, correlation-based sectional PHE core thermofluidic model is developed to study the impact of flow and geometrical parameters on the PHE performance, with varied parameters including the mass flowrate, surface roughness, and PHE dimensions. A process-based cost model is used to determine the impact of parameter variation on build cost. The model results show that a heat exchanger with a power density of 18.6 MW/m 3 (including sCO 2 header volume) and effectiveness of 0.88 can be achieved at a heat capacity rate ratio of 0.8. As a result, the impact of design and AM machine parameters on the cost of the PHE are assessed.

14 SOLAR ENERGY↗
DOE OSTI2025

REIMAGINING HEAT EXCHANGERS FOR NEXT GENERATION ENVIRONMENTAL SYSTEMS

Air-to-refrigerant heat exchangers (HXs) are essential components in space conditioning, refrigeration, and power systems, and recent efforts have focused on making these devices more compact, reducing refrigerant charge and lowering manufacturing costs. Historically, HX innovation has been limited by available computational resources, design tools, and manufacturing constraints. The best available technologies utilize tube-fin and micro- or macro-channel tubes with fins, which are not necessarily the optimal designs achievable with current technology. In this paper, we highlight the latest advancements in air-to-refrigerant HXs, specifically emphasizing innovations achieved through shape and topology optimization. A multi-scale design optimization approach is introduced, alongside similar methods in literature, which enable highly sophisticated shape-optimized tube designs with more than 50% reduction in size and 25% reduction in refrigerant charge, essential for A3 refrigerant charge limit compliance. The frameworks integrate traditional heat and mass transfer science with state-of-the-art machine learning, genetic algorithms, and adjoint algorithms to create novel designs. While many of these innovative designs may not be manufacturable using conventional methods, they allow us explore the boundaries of what is possible. These novel air-to-refrigerant HXs are key enablers for ultra-low-refrigerant charge heat pump and refrigeration systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Heat exchangers and related systems and methods

A heat exchanger may include a main body with an inlet plenum and an outlet plenum at a first end, and a header at a second end. At least one elongated shaft may extend from the outlet plenum to the header. At least one heat pipe may be coupled to the header and a portion of each heat pipe may be positioned within a corresponding elongated shaft defining an annular space between each heat pipe and each corresponding elongated shaft. A flow skirt may include a manifold located between the inlet plenum and the outlet plenum of the main body. At least one elongated tube may extend from the manifold. Each elongated tube may be positioned within a corresponding annular space between each heat pipe and each corresponding elongated shaft, dividing the annular space into two concentric annular channels comprising an inner annular channel and an outer annular channel.

Yoon, SuJong↗