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A heat exchanger incorporates a metal hydride heat exchanger and mitigates the fluid mixing process, and thus greatly improves the heat transfer efficiency and heat recovery processes. The metal hydride heat exchanger has a container for the metal hydride that has a large aspect ratio. A plurality of high aspect container for the metal hydride may be coupled with a manifold.
A system for draining an airfan heat exchanger includes an airfan heat exchanger including a housing, a pressurized gas source fluidly coupled to the airfan heat exchanger and configured to hold a purging gas at a predetermined pressure, and a controller configured to control delivery of the purging gas to the airfan heat exchanger. The pressurized gas source is configured to provide a flow of the purging gas to the airfan heat exchanger and thereby drain water held in the airfan heat exchanger. The purging gas to the airfan will cause the airfan to drain quickly avoiding potential damage to the airfan from freezing of the water during cold weather.
Microchannel heat exchanger technology is being pursued for next generation CSP concepts for primary power cycle heat addition and power cycle heat recuperation due to the high heat transfer coefficients and pressure containment advantages of small sCO 2 channels. The economics of future CSP plants as dictated by the SETO 2020 or 2030 targets depend on a heat exchanger with a 30-year lifetime (resisting creep, fatigue, corrosion, erosion) and operational characteristics such as fast ramping and the ability to withstand thermal shock. However, the lifetime and operational limits of microchannel heat exchangers operating at high-temperatures, particularly those constructed from high-nickel alloys, are not well known. This uncertainty has resulted in heat exchanger vendors not being able to accurately forecast heat exchanger lifetime as required by customers, specify operational limits as required by process engineers to prevent premature heat exchanger failure, or overdesign heat exchanger which leads to higher cost than necessary. Our goal is to evaluate heat exchanger lifetime and operational limits for the manufacturing and prototype design for next-generation CSP heat exchanger technology through a combination of collecting experimental data and modeling studies.
The objective of this study is to experimentally evaluate two residential split heat pumps using low-GWP refrigerants, i.e., R452B and R454B, and compare the results against R410A. In this work, each heat pump used the same model of two-speed scroll compressor, the same indoor blower and outdoor fan. However, they were distinguished by the indoor and outdoor heat exchanger types: tube-fin heat exchangers (TFHXs) in one case, and microchannel heat exchangers (MCHXs) in the other. The two heat pumps were extensively evaluated following the test conditions for two-speed SEER (cooling seasonal energy efficiency rating)/HSPF (heating seasonal performance factor) ratings.In general, these results show that R452B and R454B are good replacement candidates for R410A for heat pump using tube-fin heat exchangers and microchannel heat exchangers. R452B and R454B led to lower capacities. In the TFHX heat pump, on average, compared to the performance of R410A, the cooling capacity of R452B is 96%; the heating capacity of R452B is 91%; the cooling capacity of R454B is 95%, the heat capacity of R454B is 89%. In the MCHX heat pump, the cooling capacity of R452B is 97%; the heating capacity of R452B is 97%; the cooling capacity of R454B is 98%, the heat capacity of R454B is 97%. With respect to cooling and heating seasonal performances, in the TFHX heat pump, the SEERs of R452B and R454B are 1.5% lower than R410A. HSPFs of the three refrigerants are identical. In the MCHX heat pump, R454B has 7% higher SEER, and R452B has 2% higher SEER than R410A; in heating mode, R454B has the same HSPF as R410A, while R452B is 4% more efficient. The compressor lubricant overheating issue of R452B and R454B, at low ambient heating condition, high stage, should be noticed.
On-line structural health corrosion monitoring in advanced lead fast reactor heat exchangers and molten salt reactor heat exchangers is desirable for detecting tube degradation prior to leaks that may allow mixing of heat exchanger fluids or release of radiological contamination beyond the design containment boundary. This program, On-Line Lead/Water Heat Exchanger Sensor/System Feasibility – PNNL 76092, demonstrates feasibility for an ultrasonic torsional wave mode sensor attached to the outside of a long (30.5-m) heat exchanger tube in the stagnant flow area where the tube joins a heat exchanger plenum and where it is possible to protect a sensor and cable from high-force flows. The sensor must be cable connected to a monitoring instrument near the heat exchanger. The sensor and cable management approach for periodic in-service inspection will be impractical to implement on existing heat exchangers; rather permanently mounted sensors must be installed in conjunction with heat exchanger fabrication. Previous work has shown low-temperature lead zirconate titanate (PZT) piezoceramic sensors are able to detect anomalies of interest in 3.0-m long tubes. These sensors have hereby been extended to a 30.5-m long tube more representative of commercial power heat exchanger designs. The program will continue to investigate higher temperature piezoelectric ceramics and long-term performance of high temperature adhesives and sealants and mechanical pressure coupling for 350-500 °C lead reactor environments and higher temperature (700 °C) molten salt environments.
The following report aims to create a refined and well-structured method for comparatively evaluating heat exchanger technologies for integrated energy systems that caters customers’ specific needs while meeting engineering requirements. For the evaluation, this study elevates previous evaluation metrics, enhances the knowledge base via literature and market surveys, and identifies the figures of merit with robust rationales to enhance the quality of decisions made throughout the proposed heat exchanger evaluation process. The heat exchanger designs evaluated as part of the case study are shell and tube heat exchangers, printed circuit heat exchangers, plate heat exchangers, spiral heat exchangers, and heat pipe heat exchangers. The information presented in this report is meant for industries interested in making a preliminary screening process to identify the most suitable heat exchanger design for their application of interest.
The following report aims to create a refined and well-structured method for comparatively evaluating heat exchanger technologies for integrated energy systems that caters customers’ specific needs while meeting engineering requirements. For the evaluation, this study elevates previous evaluation metrics, enhances the knowledge base via literature and market surveys, and identifies the figures of merit with robust rationales to enhance the quality of decisions made throughout the proposed heat exchanger evaluation process. The heat exchanger designs evaluated as part of the case study are shell and tube heat exchangers, printed circuit heat exchangers, plate heat exchangers, spiral heat exchangers, and heat pipe heat exchangers. The information presented in this report is meant for industries interested in making a preliminary screening process to identify the most suitable heat exchanger design for their application of interest.
A method of manufacturing a heat exchanger array that includes stacking a plurality of heat exchanger units in an aligned configuration with respective first ports of the plurality of heat exchanger units aligned. The method can further include generating heat in the first coupling elements at the same time and at a temperature sufficient to generate a first plurality of respective couplings between adjacent sheets of adjacent heat exchanger units about adjacent first ports and without a coupling being generated between the first and second sheets of a given heat exchanger unit.
The ceramic-based heat exchanger is one of the leading contenders for high-efficiency concentrating solar power plants using a molten salt heat transfer fluid and a supercritical carbon dioxide Brayton power cycle operating at temperatures above 700 °C due to the excellent resistance of ceramics to corrosion, oxidation, erosion, creep, and fouling. In the present study, the thermal performance of a ceramic silicon carbide prototype heat exchanger, with semi-elliptical heat transfer channels, integrated header channels, and a counterflow configuration fabricated by using binder jetting additive manufacturing, was experimentally investigated. Experimental heat transfer tests of the prototype were conducted at high temperatures and under various test fluid flow rates and inlet temperatures. The experimental heat transfer rates compared favorably with simulation predictions.
Those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. One major barrier to wider HPWH adoption is the added equipment required, which prevents current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). PCMs have been studied extensively in building envelope and HVAC systems, but remain a nascent technology in residential water heating. While water itself has a uniquely high energy storage capacity, PCMs have an even higher energy storage density, thus providing the potential to elevate the performance of 40-gallon HPWHs to that of 50-gallon or larger tanks. This research is part of a larger project that seeks to utilize thermal energy storage to enable decarbonized water heating in low-income communities. In this study, we outline the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. In order to ensure optimal PCM utilization and tank storage capacity, we focus here on co-maximizing surface area and PCM volume in the heat exchangers; therefore, this research targets triply periodic minimal surface (TPMS) lattices. TPMS lattices boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries and offer highly tailorable designs; thus, they pair well with the growing field of additive manufacturing, or 3D printing. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives.
Abstract Many energy systems demand heat transfer at high temperatures to keep up with high demand for power, so high‐temperature material that can perform and last under these harsh conditions is needed for heat exchangers. The engineering requirements for these high‐temperature heat exchanger material call for high thermal conductivity, high resistance to fracture, high resistance to creep deformation, environmental stability in environments associated with the application, and high modulus of elasticity while maintaining low cost to make and maintain. Naturally, ceramics are a good solution for this endeavor. In the past, high‐temperature heat exchangers made from ceramics have been used. We provide examples of ceramics in relevant heat exchange applications and provide motivation where additive manufacturing (AM) can improve efficiency. AM for the relevant material is under development, and we provide insight on the AM of ceramic materials and examples of AM heat exchangers keeping cost in mind. The motivation of the review paper is to provide a framework for material and manufacturing selection for high‐temperature heat exchangers for AM to keep up with the demand for better efficiency, better material, better manufacturing, and cost moving forward with AM technology in high‐temperature ceramic heat exchangers.
Compact diffusion bonded heat exchangers are essential for high pressure heat exchange, but they are subject to thermal fatigue and ramp rate limitations. Simulation of these geometries is challenging with a large range of length and time scales from thousands of mm-sized microchannels inside a m-sized heat exchanger. Multi-physics simulations including thermal, fluid, and solid mechanics components are being used to predict stress within the heat exchangers under these conditions. These predictions can then be used to understand thermal ramp rate limitations while keeping maximum stresses low as well as fatigue life predictions from well-known empirical models.
Fin-and-tube heat exchangers (FTHEs) are widely used for high-temperature flue-gas heat recovery, but their performance is often limited by wake regions and non-uniform fin-surface temperatures. This study proposes and numerically evaluates four bio-inspired longitudinal vortex generator (VG) configurations in a high-temperature FTHE with flue-gas inlet temperature ∼1230 K: double-delta, curved double-delta, alula, and a new curved-alula geometry. The reference fin is not hydraulically plain; it already incorporates leading-edge separation columns and convex protrusions, so the alula-type winglets are assessed as downstream add-ons acting on a strongly disturbed flow. In a second step, perforations (one, two and three circular holes) are introduced into the curved-alula VGs to further tailor the flow field. Three-dimensional simulations with the Shear Stress Transpor (SST) $k - ω$ model, temperature-dependent flue-gas properties and conjugate conduction are carried out for gas-side Reynolds numbers $Re_g ≈ 8.0$ x $10^2 - 3.6$ x $10^3$ (mass flow rates 0.5 – 2.5 g/s), and the designs are compared in terms of surface heat flux, Nusselt number, friction factor and hydrothermal performance factor (HTPF). For this already-promoted fin, the additional downstream winglets provide moderate, incremental hydrothermal gains. At the highest Reynolds number, the best non-perforated design (curved-alula) increases surface heat flux from 1630.9 to 1794.7 kW/m² (∼ 10 % gain) and the Nusselt number from 227.6 to 242.6 (∼ 7 % gain), while the friction factor rises from 0.26 to about 0.30, yielding HTPF values close to unity (∼ 0.9 – 1.0). Introducing circular perforations into the curved-alula winglets acts mainly as a wake-bleeding refinement: the three-hole configuration provides a heat flux of 1824.7 kW/m² and a pressure drop of 127.9 Pa, with HTPF in the range ∼ 1.03 – 1.14 and a small (∼ 1 – 3 %) improvement over the solid curved-alula design. Flow-field analysis shows that the perforated curved-alula VGs shrink tube-wake regions, thin the thermal boundary layer and homogenize the fin-surface temperature (outlet-gas temperature ∼ 510 – 520 K and fin-surface temperature ∼ 420 – 421 K for the three-hole case). An optimal flue-gas mass flow rate of ∼ 1 g/s ($Re_g ≈ 1.5$ x $10^3$) is identified, beyond which additional heat-transfer gains are offset by rapidly increasing pressure losses. Overall, the results highlight that initial fin geometry and VG placement are as important as VG shape: alula-based winglets are expected to yield larger relative gains on simpler flat-fin layouts or when positioned closer to the fin leading edge and tube
A heat pipe reactor may include a reactor core and one or more heat exchangers positioned on one or both sides of the reactor core. The heat pipe reactor may also include a plurality of heat pipes extending from the reactor core and out through the one or more heat exchangers. The reactor core may be composed of a plurality of monolithic blocks.
Multiphysics and analytical calculations were conducted for a heat exchanger with passive, natural circulation flow. A glycol/water working fluid convects the heat to a dimpled heat exchanger shell, which subsequently transfers the heat to the soil, which acts as the ultimate heat sink. Because the system is fully-passive, it is not subject to the expenses, maintenance, and mechanical breakdowns associated with moving parts. Density, heat capacity, and thermal conductivity material properties were measured for various soil samples, and subsequently included as input for the soil heat conduction model. The soil model was coupled to a computational fluid dynamics (CFD) heat exchanger model that included the dynamic Smagorinsky large eddy simulation and k- omega turbulence models. The analysis showed that the fluid dynamics and heat transfer models worked properly, albeit at a slow pace. Nevertheless, the coupled CFD/heat conduction simulation ran long enough to determine a key parameter—the amount of heat conducted from the heat exchanger to the ground. This unique performance value, along with experimental data, was used as input for stand-alone, fast-running CFD models, as well as boundaries to obtain solutions to partial differential equations for soil heat conduction.
Microchannel heat exchanger technology is being pursued for next generation CSP concepts for primary power cycle heat addition and power cycle heat recuperation due to the high heat transfer coefficients and pressure containment advantages of small sCO 2 channels. The economics of future CSP plants as dictated by the SETO 2020 or 2030 targets depend on a heat exchanger with a 30-year lifetime (resisting creep, fatigue, corrosion, erosion) and operational characteristics such as fast ramping and the ability to withstand thermal shock. However, the lifetime and operational limits of microchannel heat exchangers operating at high temperatures, particularly those constructed from high-nickel alloys, are not well known. This uncertainty has resulted in heat exchanger vendors not being able to accurately forecast heat exchanger lifetime as required by customers, specify operational limits as required by process engineers to prevent premature heat exchanger failure, or overdesign heat exchanger which leads to higher cost than necessary.
This report proposes a novel heat exchanger evaluation method, based on integrated QFD-AHP technique, to support strategic optimal selection of heat exchanger (HX) technology for integrated energy systems. The term “optimal selection” is defined as selecting a product (i.e., HX) that best meets various aspects of end user demand, including both technical and economic requirements. Compared to previous HX evaluation methods, the proposed approach allows decision makers to explicitly take into account the practical demand of customers (i.e., HX end users) which may vary depending on the HX application target. In addition, the proposed evaluation method can be used not only for high-level decisions to select HX type, but also for low-level decisions such as the selection of the key components including HX material or heat transfer fluid. The focus of this study is to describe the new HX evaluation method and to illustrate the overall HX evaluation and selection processes using the three nuclear heat application cases that represent the thermal integration between advanced nuclear reactors and industrial processes. As a preliminary study, three different types of HX, i.e., shell-and-tube heat exchanger, printed circuit heat exchanger, and heat pipe heat exchanger, were compared.
Particle-based concentrating solar power systems integrated with sCO 2 power cycles offer high thermal efficiencies but require durable heat exchangers to transfer heat from high-temperature particles to the sCO 2 working fluid. Here, this study presents the design and optimization of a silicon carbide-silicon moving packed-bed heat exchanger for fabrication via binder jetting additive manufacturing. The heat exchanger was designed to withstand a 20 MPa sCO 2 pressure and operate at particle inlet temperatures up to 750 °C. The final design features 152 sCO 2 channels distributed across 19 plates, with elliptical corners and a minimum wall thickness of 3 mm. Flow restrictors at the sCO 2 channel inlets significantly improved flow uniformity, reducing thermal stresses and achieving a structural reliability of 99 % under representative operating conditions. The heat exchanger delivers a thermal duty of 9 kW and a volumetric power density of approximately 1 MW/m 3 in the channel region. Sensitivity studies confirmed the heat exchanger’s robustness under varying operating conditions, demonstrating its viability as a high-performance alternative to metallic heat exchangers for particle-based high-temperature concentrating solar power applications.