Advanced industrial ceramic heat pipe recuperators

Abstract

This paper summarizes the results of an investigation involving the use of ceramic heat pipe recuperators for high-temperature heat recovery from industrial furnaces. The function of the recuperator is to preheat combustion air with furnace exhaust gas. To maximize fuel savings, a very high air preheat temperature is desirable; this necessitates the use of ceramic elements in the recuperator. The heat pipe recuperator comprises a bundle of individual ceramic heat pipes acting in concert, with a partition separating the air and exhaust gas flow streams. The heat pipe fluid is a liquid metal. The ceramic heat pipe recuperator concept offers several advantages as compared to tubular type ceramic recuperators. Because each heat pipe is essentially an independent heat exchanger, the failure of a single tube does not compromise recuperator integrity and has only a minimal effect on overall heat exchanger performance. This independent element characteristic also enables easier replacement of individual heat pipes in the recuperator. In addition, the heat pipe acts as an essentially isothermal heat transfer device, leading to a high thermodynamic efficiency. Cost estimates developed for heat pipe recuperator systems indicate favorable payback periods. Laboratory studies have demonstrated the feasibility of fabricating the required ceramic tubes, coating the inside of the tubes with CVD tungsten (which functions as both a protective layer and a heat pipe fluid wick), and sealing the heat pipe with an electron-beam-welded or vacuum-brazed end cap.