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Results for “Compact heat exchanger”

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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131 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Thermal Management System of an Outer-Rotor-Motor-Based Traction Drive With Integrated Power Electronics in its Central Cavity

Increasing power densities of electric vehicle traction drive systems necessitates combining the electric motor and the power electronics into one unit. A compact, integrated traction drive unit with fewer components also drives production costs down, enabling wider adoption of electric vehicles. However, the integration of power electronics in the electric machine is associated with challenges of designing an effective thermal management solution for the combined traction drive system. This paper focuses on the thermal management approach selected for Oak Ridge National Laboratory’s outer-rotor-motor-based integrated traction drive and evaluates its potential performance. The outer-rotor-motor configuration provided an opportunity for integration of the six-phase inverter in the available space in the central cavity of the internal stator. A cylindrical inverter enclosure with integrated coolant (water-ethylene glycol) channels in its walls was designed to enable heat removal from the power electronics. Numerical thermal-fluid modeling and initial channel/fin optimization results for the cylindrical heat sink are presented here. As permanent magnets are integrated in a high-speed (20 000 RPM) outer rotor, forced air convection provides cooling for the magnets. The magnets were segmented axially to mitigate the eddy current losses. Heat generated in the stator windings and laminations is removed by water-ethylene glycol coolant circulating in interpolar T-shape ceramic heat exchangers inserted between windings. General design concepts and numerical thermal-fluid simulations illustrating the electric motor thermal management solution are also presented.

Kekelia, Bidzina↗
DOE OSTI2020

A microchannel shell-and-tube absorber for ammonia-water absorption

A shell-and-tube absorber with microscale geometric features that yields significant volumetric heat duties is investigated. A vertically-oriented baffled shell-and-tube heat exchanger with a tightly packed tube bundle is designed to serve as the absorber for a 10.5 kW nominal cooling capacity absorption chiller. The heat and mass transfer in this absorber is investigated experimentally at operating conditions spanning a wide range of working fluid and coupling fluid flow rates and ambient temperatures. An experimental facility is fabricated to closely simulate the operating conditions in an absorption refrigeration system. Absorption heat duties in the range of 5-15 kW are measured. In addition to operating the absorber in the baseline co-current flow configuration with premixed inlet, fluid ports are provided to enable operation in counter-current flow, where the dilute solution enters from the top and vapor enters from the bottom. The performance of these two flow configurations is compared. A preliminary heat and mass transfer model is developed to quantify the local temperatures, concentrations, and mass flow rates of the solution and vapor streams along the length of the absorber. The model predictions for total heat duty agree with the experimental results within 10% for almost all the data points, with an AAD of ~3.4%. Finally, the results of this study, along with the modeling framework, can guide further development of highly compact and efficient absorbers absorption systems.

42 ENGINEERING↗
DOE OSTI2021

Energy Exascale Earth System Model v2.0

First release of version 2 of the Energy Exascale Earth System Model. The atmosphere component remains EAM. Major changes since version 1 include: all column-physics parameterizations are computed on a separate grid that has approximately half the number of points of the dynamics grid, a new nonhydrostatic dynamical core (running in hydrostatic mode) with semi-Lagrangian tracer transport, CLUBB updated from v1 to v2, a new convective trigger (dCAPE/ULL) based on the dynamic Convective Available Potential Energy (CAPE) (dCAPE) and the Unrestricted Launch Level (ULL) concepts is used in ZM. minimum cloud droplet number changed, gravity wave drag energy conservation fixed and new tunings used, dust emission size distribution changed to emit more coarse dust particles The land component is still ELM. Major changes since version 1 include: using SNICAR-AD for radiation in snow to match the sea-ice model and fixing bugs in snow compaction and water state calculation. The ocean component remains MPAS-ocean. Major change since version 1 include: Redi isopycnal mixing has been updated, tested, and tuned in combination with the Gent-McWilliams parameterization, a sign error was fixed in the 3rd-order flux routines, the mesh used in low-resolution coupled cases was modified and the time steps adjusted, new regionally refined meshes were created, one focused on North America and another on the Southern Ocean, including ice shelf cavities. The sea-ice component remains MPAS-seaice. Major changes since version 1 include: A new heat- and freshwater-conserving coupling of frazil ice, turning off of SSH filtering, addition of SNICAR-AD and snow grain aging. The land-ice component remains MPAS-Albany-landIce (MALI) and is a static ice sheet. There is more out-of-the-box support for cryosphere configurations including the new regionally refined configuration around Antarctica with ice shelf cavities. The river model is MOSART. The half-degree river mesh was redone so it no longer treats Black and Caspian seas as ocean. The coupler remains cpl7/MCT. Major changes since version 1 include handling of ice shelf melt fluxes (heat / freshwater exchange with the ocean), and data icebergs. All components allow regional refinement of their meshes and two separate example of refinement, one in and around North America and one around Antarctica and the Southern Ocean, are provided.

E3SM Project, DOE↗
DOE OSTI2026

Development of a High-Efficiency Hybrid Dry Cooler System for sCO 2 Power Cycles in CSP Applications

This project addressed a major gap in supercritical CO 2 (sCO 2 ) power cycle research by focusing on the pre-cooler, a component that had received little attention despite its significant impact on cycle efficiency and plant economics. The team developed a compact dry cooler using brazed/diffusion-bonded microchannel passages paired with formed air-side fins, advancing the technology from TRL-2 toward commercial readiness. Compared to conventional fin-tube coolers, the design cuts installation footprint by roughly half for 10+ MWth systems while achieving better heat transfer and lower approach temperatures, translating into a projected LCOE reduction from 6.04 ¢/kWh to between 5.85 and 5.94 ¢/kWh. While fabrication of an aluminum MW-scale prototype revealed brazing and sealing challenges at larger scales, lessons learned informed a subsequent 1 MWth unit that was successfully built and delivered for integration into Sandia's Gen3 Particle Pilot Plant, advancing the technology to TRL-7 with a path toward TRL-8 pending successful testing.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Design, optimization, and validation of a triply periodic minimal surface based heat exchanger for extreme temperature applications

Heat exchanger (HX) innovation offers potential for significant improvements in energy efficiency for a host of applications including but not limited to aviation and power generation cycles. Triply Periodic Minimal Surfaces (TPMS) have received significant attention in recent years due to their incredibly high surface area density, which makes them very attractive from a heat transfer point of view. Recent efforts have largely focused on thermal-hydraulic characterization of the many available TPMS and the testing of small-scale HX prototypes. However, practical implementation remains largely unexplored, partially due to the extreme computational cost associated with accurately simulating these complex structures. In this work, we present the design, simulation, and optimization of a TPMS-HX for high temperature (900 °C) and pressure (25 MPa) applications. Detailed analysis of HX sub-sections is conducted to define the smallest repeatable section which may be used to characterize the thermal-hydraulic performance of the entire HX, enabling rapid design and iteration with significantly reduced computational cost. Compared to preliminary results for a water-to-water experiment, calibrated heat transfer and pressure drop predictions were within ±5 % and ±10 %, respectively. Optimization results show a 10x increase in volumetric power density over the initial design, which is verified against a parametric exhaustive search of the HX design space. Furthermore, it was found that reducing the unit cell hydraulic diameter cell plays the largest role in increasing heat transfer, increasing the surface area density and enabling a more compact and efficient HX.

42 ENGINEERING↗