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DOE OSTI2024

Heat transfer coefficients of moving particle beds from flow-dependent thermal conductivity and near-wall resistance

Accurate determination of heat transfer coefficients for flowing packed particle beds is essential to the design of particle heat exchangers and other thermal and thermochemical equipment. While such dense granular flows mostly fall into the well-known plug-flow regime, the discrete nature of granular materials alters the thermal transport processes in both the near-wall and bulk regions of flowing particle beds from their stationary counterparts. As a result, heat transfer correlations based on the stationary particle bed thermal conductivity could be inadequate for flowing particles in a heat exchanger. Most earlier works have achieved a reasonable agreement with experiments by treating granular heat transfer media as a plug-flow continuum with a near-wall thermal resistance in series. However, the thermal conductivity values of the continuum were often obtained from measurements on stationary beds owing to the difficulty of flowing bed measurements. In this work, it was found that the properties of a stationary bed are highly sensitive to the method of particle packing and there is a decrease in the particle bed thermal conductivity and increase in the near-wall thermal resistance, measured as an effective air gap thickness, on the onset of particle flow. These variations in thermal conductivity of stationary and flowing particle beds can lead to errors in heat transfer coefficient calculations. Therefore, the heat transfer coefficients for granular flows were calculated using experimentally determined flowing particle bed thermal conductivity and near-wall air gap for ceramic particles – CARBO CP 40/100 (mean diameter = 275 µm), HSP 40/70 (404 µm) and HSP 16/30 (956 µm); at velocities of 5–15 mm·s –1 ; and temperatures of 300–650 °C. The thermal conductivity and air gap values for CP 40/100 and HSP 40/70 were further used to calculate heat transfer coefficients across different particle bed temperatures and velocities for different parallel-plate heat exchanger dimensions. Furthermore, these calculations, which show good agreement with measured HTC values reported in literature, can be used as a guide for heat exchanger designs. Graphical abstract

14 SOLAR ENERGY↗

DOE OSTI2023

IDAES-PSE 2.3.0 Release

The Institute for the Design of Advanced Energy Systems (IDAES) Integrated Platform is a versatile computational environment offering extensive process systems engineering (PSE) capabilities for optimizing the design and operation of complex, interacting technologies and systems. IDAES enables users to efficiently search vast, complex design spaces to discover the lowest cost, most environmentally sustainable solutions while supporting the full process modeling lifecycle, from conceptual design to dynamic optimization and control. The extensible, open platform empowers users to create models of novel processes and rapidly develop custom analyses, workflows, and end-user applications.. New Features and Models • New diagnostics toolboxes and examples o Tutorial for using the DiagnosticsToolbox o Methods to identify potential evaluation errors in models o SVDToolbox for performing singular value decomposition analysis on models to identify possible degeneracies and poor scaling o DegeneracyHunter for identifying irreducible degenerate sets in models • Model for solid-liquid separation which takes two inputs (solid and liquid streams) and produces three outlets (solids, liquid entrained with solids and pure liquid) • Example of temperature swing adsorption in models_extra Deprecation Warnings • With the update to Pyomo 6.7.0, the plate heat exchanger model has begun failing tests on some CI platforms. If this is not addressed by the February release, this model may be removed due to failing tests. See #1294. Offers to help identify the cause and fix this issue are welcome. Improvements and bug fixes • Fixed oversight which precluded using Mixer and Separator models when inherent reactions were present in property package • Added reporting methods to the MSContactor model • Minor corrections in some examples where values were being fixed outside of declared variable bounds

DiagnosticsToolbox,IDAES,PSE,Process Systems Engin↗

DOE OSTI2024

Multifunctional Heat Pump with Energy Storage Capability

Replacing gas furnaces with heat pumps on a large scale can pose challenges to the electrical grid. It will significantly increase the demand, strain the electrical grid, especially during peak usage times. To ensure that heat pumps contribute to reducing emissions, it's essential to increase the share of renewable energy in the grid. However, the supply of renewable energy is unstable. Large scale of electrification must address the concern of grid resilience to meet necessary heating/cooling demands and shift peak electric load. All these require future heat pumps having energy storage capability. These systems can store excess energy during low-demand periods and release it during high-demand periods, reducing stress on the grid. This paper will introduce an innovative configuration, control, and laboratory investigations of a multifunctional packaged heat pump. In addition to the original indoor and outdoor air coils, the heat pump has a parallel hydronic loop with a brazed plate heat exchanger (BHP). The hydronic loop circulates hot/chilled water to store heating/cooling energy in phase change material (PCM). It is capable of space cooling, space heating, cooling energy storage/defrosting, water heating/heating energy storage with outdoor air source or indoor air source, and cooling/heating energy free discharge. The laboratory studies and breadboard unit are presented. Additionally, building energy simulation demonstrates utility cost reduction potential via charging PCM panels/ceilings during off-peak hours and releasing the energy during peak hours to mitigate the peak power consumption.

Shen, Bo↗

DOE OSTI2024

“Max-tech FHR”: What is the maximum technically achievable water delivery capacity from a single 120 V plug?

Electrifying water heating will require affordable, direct drop-in replacements for existing gas water heaters that meet consumer expectations for hot water delivery. For many replacement scenarios, affordability requires a replacement option with like-for-like physical product dimensions, and existing consumer expectations presume a large delivery capacity from a small water heater. This work explores the technical potential for hot water delivery capacity for a heat pump water heater (HPWH) powered from a common 120 V plug. Delivery capability in this work is quantified by two metrics: the First Hour Rating (FHR) defined in the Code of Federal Regulations, and a real-world draw profile that resulted in hot water runout during field studies of 120 V HPWHs. The work focuses on the common “tall-and-slim” gas water heater product category, with external product dimensions of 20 inch diameter and 60 inch height. Using a simulation model in DOE/ORNL Heat Pump Design Model, validated by experimental baseline testing of a commercially available 120 V HPWH model, several measures were evaluated to maximize the delivery capacity of a 120 V HPWH. The 120 V HPWH was constrained by 1) external product dimensions of 20 in diameter and 60 inch height, 2) electrical power of 1.5 kW (85% of the available power from a dedicated 120 V, 15 A circuit), and 3) commercially-available components. The measures implemented included a large compressor, a pumped loop with plate heat exchanger to maximize tank stratification, enlarged heat exchangers, and relatively thin insulation to maximize the water storage volume.

Gluesenkamp, Kyle↗

DOE OSTI2025

Fabrication of the HFVMTF Double-Bath Cryostat

The High Field Vertical Magnet Test Facility (HFVMTF) at Fermilab is designed to test superconducting magnets up to 20 tons and 1.3 meters in diameter. Central to the facility is a double-bath superfluid helium cryostat reaching 1.8 K at 1.2 bar. Integrated with a 15 T superconducting dipole from LBNL, HFVMTF supports HTS cable testing for fusion applications. This paper presents the design and fabrication of the cryostat, with a focus on two complex components: the 2 K heat exchanger and the lambda plate. The heat exchanger thermally links sub-atmospheric and pressurized helium baths. The 1.4-meter lambda plate provides thermal isolation and structural support for over 20 tons under 1.3 bar pressure differential. Finite Element Analysis validated the vessel’s integrity under maximum load conditions.

Bruce, Romain [Fermilab] (ORCID:0000000234200612)↗

DOE OSTI2025

Fabrication of the HFVMTF Double-Bath Cryostat

Bruce, R. [Fermilab] (ORCID:0000000234200612)↗

DOE OSTI2024

Two-Fluid and Discrete Element Modeling of a Parallel Plate Fluidized Bed Heat Exchanger for Concentrating Solar Power

A novel high-temperature particle solar receiver is developed using a light trapping planar cavity configuration. As particles fall through the cavity, the concentrated solar radiation warms the boundaries of the receiver and in turn heats the particles. Particles flow through the system, forming a fluidized bed at the lower section, leaving the system from the bottom at a constant flowrate. Air is introduced to the system as the fluidizing medium to improve particle heat transfer and mixing. A laboratory scale cavity receiver is built by collaborators at the Colorado School of Mines and their data are used for model validation. In this experimental setup, near IR quartz lamp is used to provide flux to the vertical wall of the heat exchanger. The system is modeled using the discrete element method and a continuum two-fluid method. The computational model matches the experimental system size and the particle size distribution is assumed monodisperse. A new continuum conduction model that accounts for the effects of solid concentration is implemented, and the heat flux boundary condition matches the experimental setup. Radiative heat transfer is estimated using a widely used correlation during the post-processing step to determine an overall heat transfer coefficient. The model is validated against testing data and achieves less than 30% discrepancy and a heat transfer coefficient greater than 1000 W/m2 K.

concentrating solar power↗

DOE OSTI2024

End-Use Savings Shapes: Measure Documentation: Add Exhaust Air Heat/Energy Recovery

This documentation focuses on a single end-use savings shape measure—Add Exhaust Air Heat/Energy Recovery. This measure adds exhaust air energy recovery or heat recovery to existing air handling units (AHU) with outdoor air. Systems that already have energy/heat recovery are not modified. Furthermore, food service building types are also not modified by this measure due to the added complication of integrating cooking hood exhaust that could cause heat exchanger fouling from kitchen exhaust. In total, this measure is applicable airloops serving ~70% of the floor area in ComStock. In practice, energy/heat recovery systems are retrofitted to existing air delivery systems either as separate systems that provide outdoor air to the AHUs or are directly integrated to an AHU; the modeling approach used in this study is agnostic of the energy recovery type and simply accounts recovery effectiveness, added static pressure, and other controls which are described further in this document. Energy recovery with sensible and latent exchange gets added in humid climate zones, while heat recovery with sensible-only exchange gets added in drier climate zones. Energy recovery is modeled as a fixed membrane plate counterflow heat exchanger, while heat recovery is modeled as a sensible-only fixed aluminum plate counterflow heat exchanger. Both systems include a bypass (for temperature control and economizer lockout) and electric resistance preheat coil for frost prevention.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Demonstration of a multi-channel fluidized bed particle–supercritical carbon dioxide heat exchanger for concentrating solar applications

High-temperature thermal energy storage in oxide particles at temperatures above 600°C can couple concentrated solar energy with high-efficiency thermal power cycles to provide dispatchable solar-driven electricity. Challenges remain in developing cost-effective primary heat exchangers, which require expensive alloys, to extract the high-temperature thermal energy from the particles to power cycle fluids, such as supercritical CO 2 (sCO 2 ) in recuperated Brayton cycles. To explore one pathway for cost-effective, high-temperature particle heat exchangers, the current study demonstrates a shell-and-plate, particle–sCO 2 heat exchanger with narrow- channel fluidized beds coupled with micro-channel sCO 2 flows in the heat exchanger walls. This study evaluates the feasibility of multiple parallel, narrow-channel fluidized beds in shell-and-plate particle–sCO 2 HXs, to achieve high bed-wall heat fluxes at elevated temperatures. A reduced-order model simulates the narrow- channel, fluidized-bed particle–sCO 2 heat exchanger to design the fluidized bed geometry, in terms of depth, height, and number of channels,for a nominal 40-kWth heat exchanger at particle and sCO 2 inlet temperatures up to 600 °C and 400 °C respectively. The resulting shell-and-plate heat exchanger design operates with bubbling fluidization of the downward-flowing oxide particles to enhance bed-wall heat transfer. The heat exchanger core is fabricated with etched sCO 2 micro-channels in thin wall plates that are diffusion bonded to spacer frames to form the shell-and-plate structure with 12 parallel, fluidized bed channels, 10.4 mm deep. The heat exchanger is tested at the National Solar Thermal Test Facility at Sandia National Laboratories with CARBOBEAD HSP particles at design particle flow rates of 0.20 kg s –1 and inlet temperatures up to 525 °C. Results show that fluidization across multiple parallel channel beds can maintain uniform particle inventory with a common freeboard zone above the heat exchanger core. Bubbling fluidization improves particle–wall heat transfer coefficients but also increases axial dispersion of particle thermal energy, which lowers the log- mean temperature difference such that total heat transfer remains relatively constant to within ±10% over a broad range of fluidization gas velocities. The axial dispersion required particle and sCO 2 flow rates to be increased by 25% over model-designed conditions to achieve the targeted 40 kWth, which indicates the importance of incorporating axial dispersion into heat exchanger design models and of deploying bed structures to suppress it. Furthermore, this study demonstrates the feasibility and preferred fluidizing gas conditions for particle heat exchangers for releasing high-temperature thermal energy storage systems.

14 SOLAR ENERGY↗

DOE OSTI2020

Characterization and Scaling of Forced Convective Swirl in Sinusoidal Wavy-Plate-Fin Cores of Compact Heat Exchangers

The characterization and scaling of the thermal-hydraulic performance in wavy plate-fin compact heat exchanger cores, based on the understanding of the physical phenomena and heat transfer enhancement mechanism is delineated. Experimental data are presented for forced convection in air (Pr = 0.71) with flow rates in the range 50 ≤ Re ≤ 4000. A variety of wavy-fin cores that span viable applications, with geometrical attributes described by the cross section aspect ratio α (ratio of fin spacing to height), fin corrugation aspect ratio γ (ratio of 2× corrugation amplitude to wave pitch), and fin spacing ratio ζ (ratio of fin spacing to wave pitch), are considered. To characterize and correlate the vortex-flow mixing in interfin spaces, a Swirl number Sw is introduced from the balance of viscous, inertial and centrifugal forces. It is shown that the laminar, transitional and turbulent flow regimes can be explicitly identified by this Swirl number. Based on the experimental results and extended analysis, new correlations for Fanning friction factor f and Colburn factor j are developed with Sw, α, γ, and ζ as scaling parameters. Requisite expressions are devised by a superposition of both enhancement components due to the corrugated surface area enlargement and induced swirl flow field, and they are combined to cover the laminar, transitional and turbulent regimes by the method of asymptotic matching. The resulting generalized correlations are further shown to predict all available experimental data for f and j factors to within ±20% and ±15%, respectively.

42 ENGINEERING↗

DOE OSTI2023

End-Use Savings Shapes Measure Documentation: Variable Refrigerant Flow with Heat Recovery and Dedicated Outdoor Air System

Building on the successfully completed effort to calibrate and validate the U.S. Department of Energy's ResStock™ and ComStock™ models over the past 3 years, the objective of this work is to produce national data sets that empower analysts working for federal, state, utility, city, and manufacturer stakeholders to answer a broad range of analysis questions. The goal of this work is to develop energy efficiency, electrification, and demand flexibility end-use load shapes (electricity, gas, propane, or fuel oil) that cover a majority of the high-impact, market-ready (or nearly market-ready) measures. "Measures" refers to energy efficiency variables that can be applied to buildings during modeling. An end-use savings shape is the difference in energy consumption between a baseline building and a building with an energy efficiency, electrification, or demand flexibility measure applied. It results in a time-series profile that is broken down by end use and fuel (electricity or on-site gas, propane, or fuel oil use) at each time step. ComStock is a highly granular, bottom-up model that uses multiple data sources, statistical sampling methods, and advanced building energy simulations to estimate the annual subhourly energy consumption of the commercial building stock across the United States. The baseline model intends to represent the U.S. commercial building stock as it existed in 2018. The methodology and results of the baseline model are discussed in the final technical report of the End-Use Load Profiles project. This documentation focuses on a single heating, ventilation, and air-conditioning (HVAC) end-use savings shape measure - a variable refrigerant flow with heat recovery (VRF HR) heating and cooling system coupled with a dedicated outdoor air system (DOAS) for ventilation. This measure replaces existing multi-zone variable air volume (VAV) systems or single-zone rooftop units (RTU) with a VRF HR system coupled with a DOAS that includes an energy/heat recovery ventilator (E/HRV). The measure covers 53% of exisiting building stock's floor area and is not applicable to HVAC system types using district heating or cooling or buildings/spaces that include high-ventilation spaces such as kitchens where the amount of exhaust air is large. A DOAS with E/HRV is used to provide required outdoor ventilation air to spaces since ventilation air is generally not supplied by a VRF HR system. An exhaust air energy recovery ventilator (ERV ) with sensible and latent heat exchange is added to humid climate zones while a heat recovery ventilator (HRV ) with sensible only exchange is added to drier climate zones. The ERV is modeled as a fixed membrane plate counterflow heat exchanger, while the HRV is modeled as a sensible-only fixed aluminum plate counterflow heat exchanger. Both systems include a bypass (for temperature control and economizer lockout) and minimum exhaust temperature control for frost prevention.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Experimental Characterization of an Additively Manufactured Inconel 718 Heat Exchanger for High-Temperature Applications

This work presents the experimental results of a novel, air-to-air, additively manufactured manifold-microchannel heat exchanger with straight fins on both sides. The heat exchanger was made of Inconel 718 using a direct metal laser sintering technique. The overall core size of the heat exchanger was 94 mm × 87.6 mm × 94.4 mm, with a fin thickness of 0.220 mm on both the hot and cold sides. The heat exchanger was tested with pressurized nitrogen gas at 300 °C and 340 kPa for the hot side, while air at an ambient condition was used for the cold side. An overall heat transfer of 276 W/m2K was obtained for Reynolds number values of 132 and 79 for the cold and hot sides, respectively. A gravimetric heat transfer density (Q/m∆T) of 4.7–6.7 W/kgK and a volumetric heat transfer density (Q/V∆T) of 6.9–9.8 kW/m3K were recorded for this heat exchanger with a coefficient of performance value that varied from 42 to 52 over the operating conditions studied here. The experimental pressure drop results were within 10% of the numerical values, while the corresponding heat transfer results were within 17% of the numerical results, mainly due to imperfections in the fabrication process. Despite this penalty, the performance of the tested heat exchanger was superior to the conventional plate-fin heat exchangers: more than 60% of improvements in both gravimetric and volumetric heat transfer densities were recorded for the entire range of experimental data.

42 ENGINEERING↗

DOE OSTI2022

Parametric Modeling and Economic Analysis of a 2MW th 3-Stream sCO 2 Heat Exchanger

Here, this paper presents the design and cost optimization of a novel 2MW th 3-stream sCO2 plate-fin heat exchanger. This heat exchanger design is unique in that it uses reduced metal oxide particle-to-sCO2 heat exchanger for cost-effective energy storage applications. The design uses low velocity, laminar air as the re-oxidizing reactant to transfer the heat of the re-oxidizing reaction to a sCO2 power loop. The design of the heat exchanger is based on a 2-D, 3-fluid plate/fin heat transfer model. The model parameterizes the size, shape, and number of passages of the heat exchanger to calculate the temperature profile, pressure drop, and fluid velocities of all three fluids. Global heat exchanger parameters such as the effectiveness and total heat transferred to the sCO2 are then calculated for overall performance. Due to the value and increased use of sCO2 heat exchangers in power cycles, a cost model of the system based on the unique high temperature/high pressure operating conditions was created using quotes from reference projects and market analysis. These quoted air-to-sCO2 heat exchangers are then processed using multiple weighting factors pertinent to heat exchanger design, including heat exchanger type, maximum temperature, differential pressures, fluids, duty, and more. These factors are then used in an exponential function in order to generate a parameterized cost curve. The design and cost of the heat exchanger are then optimized using the SMPSO genetic algorithm in Python. The optimization objectives for the system are to maximize the overall system effectiveness, including an air recuperator for preheating, and to minimize unit costs. Additional constraints are added to the system for the sCO2 and air pressure drops, air velocity to reduce particle entrainment, and the length and volume of the heat exchanger.

Cost Model↗

DOE OSTI2022

Design optimization of an additively manufactured prototype recuperator for supercritical CO 2 power cycles

Supercritical CO 2 (sCO 2 ) power cycles are being developed due to their potential for high efficiency and reduced capital cost. It is necessary that these recuperators operate at high pressures and temperatures, up to 30 MPa and 900 K, with effectiveness values > 95% and pressure drops <1% to achieve high cycle efficiencies. Moreover, it is also necessary to have reasonable cost recuperators to control the capital costs of the sCO 2 power cycles. In this study, a Plate Pin-Fin (PPF) heat exchanger has been proposed as an sCO 2 recuperator. This preliminary recuperator design leverages capabilities enabled by additive manufacturing. Although the PPF design has characteristics similar to those of a plate heat exchanger, small diameter and relatively long fins are used to increase surface area, enhance heat transfer, and provide structural support for the partition plates that separate the fluid streams. Existing correlations for heat transfer and pressure drop were adapted for the PPF heat exchanger. These correlations were implemented in a 1D analytical model and used for the optimization of a 5-kW th high temperature recuperator for an indirect sCO 2 cycle by varying the design parameters to minimize the quantity of material required. A 3D conjugate heat transfer numerical simulations were conducted to validate the heat transfer and pressure loss correlations. A steepest descent method was used to minimize heat exchanger mass for a 5-kW prototype recuperator subject to a maximum specified pressure drop. Additionally, the design analysis indicated that an optimum PPF recuperator would be attained for the minimum allowable pin transverse spacing, minimum pin width, minimum pin height and near maximum cell aspect ratio. Moreover, at a low material requirement of 0.216 kg/kW and a pressure drop, which is almost five times lower than the allowable pressure drop design target, the optimized PPF heat exchanger has the high potential to be an alternative to a printed circuit heat exchanger, which is a conservative design basis for the current state-of-the-art sCO 2 recuperators.

42 ENGINEERING↗

DOE OSTI2022

Development of an Integrated Thermal Energy Storage Heat Exchanger for Concentrating Solar Power

In this design and development effort a latent-heat energy storage heat exchanger was designed for a 10MW e sCO 2 power plant as a basis for detailed design and testing of a new phase-change heat exchanger technology. High efficiency thermal conductors of graphite foam or folded copper were employed within chloride salt phase-change volumes bounded by alternating high density compact plate-fin heat exchange cells in this new heat exchanger technology. Test articles were constructed at Brayton Energy and tested at Argonne National Laboratory. Copper-conducting samples were constructed and tested at Brayton Energy.

14 SOLAR ENERGY↗

DOE OSTI2022

Multifunctional intensified reactor device with integrated heat and mass transfer

A packing device for mass and heat transfer with a subject fluid includes a housing having opposing ends, and subject fluid openings at each opposing end defining a subject fluid flow path for at least one subject fluid flowing through the packing device. A plurality of mass and heat transfer plates each include an interior heat exchange fluid channel disposed between interior heat transfer surfaces of the mass and heat transfer plates. A heat exchange fluid inlet and fluid outlet can supply and remove heat exchange fluid to the heat exchange fluid channels of the mass and heat transfer plates. The mass and heat transfer plates can be oriented to define there between fluid flow channels for the subject fluid. A method and system for mass and heat transfer with a subject fluid, and a method and system for the removal of CO2 from a gas stream are disclosed.

Lai, Canhai↗

DOE OSTI2022

Commissioning of a replacement subatmospheric cold box for Jefferson Lab’s Central Helium Liquefier

Jefferson Lab’s Cryogenics Department has designed, fabricated, installed, and commissioned a new subatmospheric cold box to replace one of the two existing units within our Central Helium Liquefier (CHL). The replacement cold box, dubbed SC1R, pumps saturated helium vapor at 0.0385 atm from Jefferson Lab’s continuous electron beam accelerator facility (CEBAF) cryomodules to maintain an operating temperature of nominally 2.1 K. This is accomplished using a five-stage cryogenic centrifugal compressor (cold compressor) system and a brazed aluminum plate-fin heat exchanger operating between 2.1 K and 4.5 K. In this paper we will describe our experience commissioning the SC1R cold box. We will discuss pump-down of the system to 2.1 K and steady-state operation at the cold compressor design flow rates of 170, 200, and 250 g/s. Performance of the heat exchanger and cold compressors has been mapped across a range of flow rates and optimized for CEBAF operations. This commissioning data will be used to monitor future performance and adapt to changing load requirements.

Mastracci, B.↗

DOE OSTI2022

Design of the cryostat for High Field Vertical Magnet Testing Facility at Fermilab

High Field Vertical Magnet Test Facility (HFVMTF) is a joint project between the Office of High Energy Physics (HEP) and the Office of Fusion Energy Sciences (FES). Its construction is currently under way at Fermi National Accelerator Laboratory (Fermilab). As a part of the project a new double bath superfluid helium cryostat has been designed. The cryostat can accommodate magnets with up to 20 tonne weight and 1.3 m diameter. This paper discusses challenges and solutions for cryostat, lambda plate and heat exchanger design, and presents results of performance analysis.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗