Microchannel and Minichannel Heat Exchangers in Advanced Energy Recovery and Conversion Systems

Abstract

Energy recovery is gaining importance in various industrial process applications because of rising energy costs and geopolitical uncertainties impacting basic energy supplies. Various advanced energy recovery / conversion technologies will require high-performance heat transfer characteristics typical of micro- and mini-channel heat exchangers to achieve energy recovery performance targets and requirements. Initial engineering scoping studies have focused on advanced thermoelectric generator (TEG) systems assuming exhaust gas temperatures of 1033 K (1400 °F) and ambient environment temperatures of 300 K. The engineering analysis used a coupled, integrated thermoelectric (TE) system analysis accounting for the heat exchange / heat transfer performance at both the hot and cold sides and optimum TE device performance to properly predict the power output potential, resulting temperatures and temperature differentials, TEG design and interface requirements, and thermal characteristics across a wide spectrum of potential operating temperature conditions. Modular TEG's capturing about 5% of typical industrial process (e.g., glass manufacturing process) exhaust flows appear to have potential power outputs of 4 - 6 kW using advanced TE materials. Hot-side & cold-side heat exchange requirements were quantified and performance metrics evaluated to enable effective implementation of advanced TEG systems in industrial process energy recovery. Hot side heat transfer requirements create serious engineering, and possibly, scientific challenges to enabling energy conversion systems, including TEG's, in industrial process energy recovery. Future advanced heat transfer R&D is necessary and should occur in parallel with on-going advanced TE materials and systems R&D.