Primary Heat Exchanger Research Articles

Numerical Modelling Of A Primary Heat Exchanger in sCO2 Power Cycles for Thermal Energy Storage Systems

Abstract Renewable energy sources are the key for long-term decarbonization of energy. However, the intermittent nature of renewables does not always meet the energy demand in the electrical grid. Thus, electrical heated Thermal Energy Storage systems (TES) coupled with sCO2 power cycles are investigated at Helmholtz-Zentrum Dresden-Rossendorf as a possible solution to balance this mismatch. In this study, a Printed Circuit Heat Exchanger (PCHE) is considered as candidate for the 1 MW primary heat exchanger, given the mechanical challenge induced by drastic pressure difference between the hot fluid of the TES and the cold fluid of the power cycle. The present work consists of two parts, one elaborates a 1D model in order to optimize the PCHE regarding the pump power required to compensate the pressure loss. It was found that the hot fluid coming from the TES accounts for 80 % of the total pump power after optimization because of its low density and its high mass flow rate. Furthermore, 3D simulations by Computational Fluid Dynamics (CFD) were done and compared to the results from the 1D model to ensure its validity. It was observed that the results from the 1D model and the CFD simulations are consistent, with a slight potential deviation in the calculation of the pressure profile.

Global sensitivity analysis of nuclear district heating reactor primary heat exchanger and pressure vessel optimization

Recently, small modular reactors (SMRs) have received greater interest as a source for clean and affordable district heating (DH). Compared to power plants, the low-pressure, low-temperature design and nearly 100 % efficiency reduce the cost of produced energy considerably. However, few practical implementations exist yet, and cost estimates and design principles are subject to uncertainties whose interactions remain largely unknown. In this work, we present a techno-economic optimization and sensitivity analysis of a natural circulation DH SMR primary heat exchanger. A Cuckoo Search variant augmented with a modified Hooke-Jeeves search was used as the optimizer, with SimDec (simulation decomposition) subsequently employed for global sensitivity analysis. The reactor pressure vessel and containment vessel specific costs exhibited the greatest impact on the cost of heat and the optimized configurations. While low-pressure, low-temperature design is central to heating reactor cost-effectiveness, optimized primary circuit temperatures clearly exceeded previous assumptions. In a 5260 full-load hours mid-load application, a 34–41 €/MWh cost range was found for produced heat at 8 % interest and 20-year lifetime. For heat exchanger optimization, the results indicate the potential for considerable performance improvement from using deterministic local search for terminal convergence and sensitivity analysis for dimensionality reduction.

The preliminary design of emergency core cooling scheme and loss-of-coolant accident analysis for Tsinghua high flux reactor

This paper proposes the preliminary emergency core cooling scheme for Tsinghua High Flux Reactor. According to the thermohydraulic characteristics of high flux reactors, forced circulation needs to be maintained by emergency pumps in the early stage. When the decay power is low enough, natural circulation between core and the reactor pool is initiated to remove the residual core heat. The sources of safety injection are accumulators and reactor pool. Accumulator injection can ensure core safety in the early stage and reactor pool injection can maintain long time stable forced circulation. To avoid emptying the reactor pool, the waterproof zone needs to be built. The waterproof zone consists of reactor pool and several finite volume dry pools. All pipelines and equipment in the reactor coolant system are placed in the dry pools. Once break accident occurs, the dry pool where the break is located can collect the leaked coolant. With the increase of break back pressure, the break flow is restricted. The current scheme is modeled by Relap5 and different size breaks at four locations (namely core inlet, core outlet, primary heat exchanger inlet and main pump inlet) are assumed. According to the response characteristics of the scheme, the accident process can be divided into five stages: non-shutdown stage, high-injection stage, low-injection stage, stable forced circulation stage and natural circulation stage. Critical heat flux predicted by Sudo CHF correlations is adopted as the primary safety criterion. Through analysis, a success path is found to maintain core safety for a wide range of loss-of-coolant accident scenarios.

Analysis on heat transfer enhancement mechanism in a cross-wavy primary surface heat exchanger based on advection thermal resistance method

This paper numerically investigates the flow and heat transfer characteristics in the primary surface heat exchanger (PSHE) with cross-wavy (CW) structures. The comprehensive performance affected by hydraulic diameters is evaluated. Moreover, the airflow shuttling behavior at the mixing area of CW-type PSHE is discussed, showing rapid heat transfer enhancement. The advection thermal resistance method and local thermal resistance analysis is proposed, while the impacts of longitudinal pitch and flowrates are considered. Results show that the case with a large hydraulic diameter displays much better comprehensive performance at lower flowrates. When raising the hydraulic diameter from 1.58 mm to 15.8 mm, the heat transfer rate per unit pumping power grows by 36.1 %. However, the priority of large channel is gradually disappeared after increasing the flowrates. Meanwhile, the larger longitudinal pitch of the CW channel may result in pronounced improvement on the heat transfer performance due to the presence of airflow shutting behavior at the mixing area as well as the secondary flow near the channel boundary layers. When no airflow shuttling exists, very high advection thermal resistance region can be observed due to the formation of boundary layers. It can be recognized that the case with airflow shuttling behavior can display similar heat transfer improvement compared to that with increasingly high Reynolds numbers, yet the pressure loss is rarely increased.

Progress in passive spent fuel pool cooling system R&D based on heat pipe technology

Following the Fukushima Daiichi Nuclear Power Plant accident, particularly the hydrogen explosion at Unit 4, the safety of spent fuel pools garnered heightened attention, and the global nuclear industry extensively studied post-accident cooling of spent fuel pools consequently. During this period, the distinguished passive capabilities of heat pipes led to their superior adoption as primary heat exchangers, gradually becoming a technical consensus in the whole field. Starting in 2016, based on the series of PEX (Passive Experimental Facility), the group led by China Nuclear Power Engineering Co., Ltd. (CNPE) commenced continuous research on heat pipe mechanisms, the design of separate plate heat exchangers, and the overall characteristics of the Passive Spent Fuel Pool Cooling System (PSFS). And in 2023, CNPE proposed the conceptual design for the Linglong One PSFS system finally. The PEX series experiments were completed in two phases using four sets of experimental apparatus: the feasibility study phase with PEX00 and PEX00+, smaller-scale experimental setups with heat power 2–10 kW, primarily addressing issues related to heat pipe mechanisms, working fluid selection, optimal filling rate, vacuum maintenance, system startup characteristics, and the engineering feasibility of separate heat pipe heat exchanger; and the prototype testing phase with PEX50K and PEX100K. PEX50K, a medium-scale conceptual prototype test facility with heat power 50–100 kW employing a novel separated plate heat pipe (SPHP), focusing on research on innovative heat pipe devices. PEX100K, a large-scale engineering prototype test facility with heat power 100–200 kW employing traditional separated tube heat pipes (STHP), aimed at performance verification of engineering prototype units. After five years of research, the SPHP-based approach was ultimately selected, while the initial one with STHP was discarded. This paper provides a comprehensive overview of CNPE's pioneering, exhaustive, and systematic research and development process on SPHP and PSFS. details the PEX series experimental apparatus, and presents the main conclusions. More detailed experimental data, discussions on specific phenomena in certain experiments, detailed descriptions of equipment's processes, and ongoing actual system-level tests will be discussed in subsequent papers.

Thermal performance of three-wheel and split-wheel air cycle systems for a civil aircraft environmental control system (ECS)

The conventional approach of regulating cabin temperature and pressure on aircraft is to utilize engine-bleed air through an environmental control system (ECS). The extraction of bleed air from the engine leads to a decrease in thrust and an increase in drag on the ECS ram air duct, resulting in higher fuel consumption. Consequently, the ECS transitioned from being engine-powered to being electrically powered. In this study, the thermodynamic characteristics of three-wheel and split-wheel air cycle systems (ACSs) with a high-pressure water separation system (HPWS) were investigated by developing a parameter decomposition model and an iterative algorithm using MATLAB for a state-of-the-art electrically driven ECS (EECS) on the Boeing 787 Dreamliner. The efficiency of the ACS was assessed by establishing analytical correlations for the coefficient of performance (COP) using relevant literature on endo-reversible thermodynamic model (ETM). By employing these analytical correlations, the thermal performance of both ACSs can be accurately predicted without the need for system modeling and simulation, considering variations in the input variables and operating conditions, such as the temperatures of fresh air and ram air, the ratio of the mass flow rates of ram air and fresh air, and component parameters, including the efficiencies of the primary and secondary heat exchangers and the pressure ratios of the fan and compressor. The implementation of a split-wheel ACS instead of three-wheel ACS in the Boeing 787 EECS led to an improvement in the COP from 0.31 to 0.43, and also resulted in a reduction of 14.35 % in the input power.

Burnup and neutronic parameter analysis of GAMA molten salt reactor (GAMA-MSR)

The GAMA molten salt reactor (GAMA-MSR) is a small modular MSR design developed by the Nuclear Reactor Research Team of the Department of Nuclear Engineering and Engineering Physics, Universitas Gadjah Mada. In the GAMA-MSR design, the reactor core is placed above the primary heat exchanger. The primary heat exchanger is partially filled with fuel in normal operation, allowing room to be filled with the fuel drained from the reactor. Thus, in addition to control rods, the design of GAMA-MSR provides unique reactivity control through the balance of fuel salt fuel from the reactor core to the primary heat exchanger vice versa by adjusting fuel pump capacity. This design allows to shutdown the reactor by switching off the fuel pump. The reactor is initially fueled with 7LiF-ThF4-UF4 with 75: 20.1: 4.9 mol composition. The uranium has 19.75 % U-235 mol fraction. The reactor criticality and nuclide composition in the reactor fuel are calculated using OpenMC code during the reactor operation lifetime, with periodic adjustments to the fuel composition to simulate the effects of the fissile and fertile additions to the fuel and the extraction of actinides and fission products from the fuel. The calculated reactor thermal power is 60 MWth in this paper. The reactor is operated until it achieves a burnup value of 34,000 MWd/tHM. At this burnup value, the U-235 inventory is consumed and the amount is reduced from 794 kg to 250 kg. The U-233, Pu-239 and Pu-241 are produced with the amount are 246 kg, 24 kg and 8 kg respectively at the end of reactor operation. The effects of temperature, fuel density change, and fission product neutron poisons are also calculated. The average temperature reactivity coefficient value is approximately -4.4395×10-5Δk/k per °C. The effect of thermal expansion has been included in the calculation of this temperature reactivity coefficient value. The average value of the void reactivity coefficient is +1.2606×10-3Δk/k per % of void fraction for the void fraction value range up to 50 %. However, molten salt fuel suffers only small changes in density during operation. The negative value of the temperature reactivity coefficient will be dominant; thus, the GAMA-MSR becomes inherently safe. The GAMA-MSR is designed for a 30-year operation time. The effect of the fission product to the reactor reactivity is -1.4597×10-2Δk/k. Full draining of the fuel to primary heat exchanger brings the reactor to shutdown condition with the reactivity of −0.20525. Results showed that this reactor has an inherently safe characteristic and has an effective shutdown system, especially due to the fuel draining system.

Investigation of cross-wavy primary surface structures for heat exchangers of Brayton cycle system using argon

In order to investigate the performance of the Cross-Wavy (CW) primary surface heat exchanger in Brayton cycle system using argon, a three-dimensional numerical model is established in this paper, and the influence of the structural characteristics of the flow channel on heat transfer and flow is analyzed in depth based on numerical simulation results. Effects of amplitude (A), height (H) and thermal channel radius (R1) on pressure loss, heat transfer and overall performance are further investigated. The results indicate that the increase in A leads to a significant rise in heat transfer performance and energy loss. Compared with the maximum and minimum amplitude simulation results, the increase in the f coefficient can reach 140%, and the increase in Nu is 31.94%. With the increase of H from 1.7 mm to 3.2 mm, f decreases by 18.75% and Nu decreases by 8.07%. Whereas, the change brought about by R1 is very small, less than 2.5%. By comparing the f coefficients with the experimental results of the biconvex stamped plate heat exchanger, the feasibility of the CW primary surface heat exchanger for application in a micro nuclear power system is verified.

APPLİCATİON OF THERMİSTORS AND THEİR CALİBRATİON

The basis of thermodynamic methods is that temperature accuracy should be high. When choosing thermal transducers, you should be guided by the following requirements for measuring equipment, the performance of which allows you to successfully use thermodynamic methods for diagnosing hydraulic machines in real working conditions: • high output signal level; • minimal inertia of heat exchangers; • high stability during operation; • minimum dimensions of primary heat exchangers; • sensitivity to vibration and shock; • sensitivity to external electromagnetic fields; • ability to use serial measuring instruments. Keywords: hydraulics; hydromechanical losses; volumetric hydraulic devices; scheme of experimental device; thermoresistor; current-voltage characteristic; NTC thermistor; hydraulic machine

Analysis of transient characteristics and design improvement of the passive residual heat removal system of NHR-200-II

NHR-200-II is a small integrated pressurized water reactor with 200 MW core thermal power. The core heat is transferred to two independent intermediate circuits via fourteen in-vessel primary heat exchangers (PHE), and the heat in the intermediate circuits is transferred to feedwater by two steam generators (SG) in the two intermediate circuits respectively. A passive residual heat removal (PRHR) branch is connected to each intermediate circuit to remove core decay heat under postulated accidents. During normal operation, PRHR branches are isolated by valves while SG branches in intermediate circuits are open. The valves in PRHR branches will be opened and the isolation valves of SG branches will be closed during decay heat removal scenarios. The decay heat removal capacity of NHR-200-II PRHRS could be seriously deteriorated once the isolation valves for SG branches fail to close, which was confirmed in a scaled integral test loop previously. Current understanding of PRHRS’s thermal-hydraulic characteristics with possible isolation failure in SG branches is limited. In this paper, the NHR-200-II PRHRS is modeled with RELAP5 considering the case of success and fail to isolate SG branches. A series of numerical simulations are carried out to study the impact of various parameters, such as the initial temperature, the size of the intermediate circuits’ header, and the initial flow direction in the intermediate circuits. Oscillatory flow is found when SG branches fail to be isolated under certain parameters combinations. An improved PRHRS design is purposed to eliminate possible flow oscillations, and the purposed improved design are tested by numerical simulations.

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 CO2 (sCO2) 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–sCO2 heat exchanger with narrow-channel fluidized beds coupled with micro-channel sCO2 flows in the heat exchanger walls. This study evaluates the feasibility of multiple parallel, narrow-channel fluidized beds in shell-and-plate particle–sCO2 HXs, to achieve high bed-wall heat fluxes at elevated temperatures. A reduced-order model simulates the narrow-channel, fluidized-bed particle–sCO2 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 sCO2 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 sCO2 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 sCO2 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. This study demonstrates the feasibility and preferred fluidizing gas conditions for particle heat exchangers for releasing high-temperature thermal energy storage systems.

Testing of a 40-kWth Counterflow Particle-Supercritical Carbon Dioxide Narrow-Channel, Fluidized Bed Heat Exchanger

Particle-based primary heat exchangers (HXs) must deliver sCO2 fluid temperatures above 700°C to couple particle-based concentrating solar receivers and thermal energy storage (TES) sub-systems with efficient sCO2 power cycles. Particle-sCO2 HX designs have struggled to meet DOE cost targets (≤ $150/kWth) due to the amount of expensive nickel alloys necessary for manufacturing full-scale, particle-sCO2 HXs. Our team has demonstrated that mild bubbling fluidization of falling particles in a counterflow narrow-channel fluidized bed can reduce required HX surface area and thus, costs by increasing particle-wall heat transfer coefficients hT,w > 800 W m-2 K-1. This paper reports on the fabrication and testing of a stainless steel, particle-sCO2 HX with 12 fluidized-bed channels approximately 10.5 mm deep spaced between diffusion-bonded, micro-channel sCO2 plates. The HX with a core length of ≈0.56 m is fed with CARBOBEAD HSP particles through a short, fluidized freeboard zone just above the core. Testing to date in the National Solar Thermal Test Facility (NSTTF) at Sandia National Laboratories has shown that parallel bed fluidization maintains uniform particle inventory across the instrumented channels. Heat transfer thermal duty between the particle and sCO2 flows exceeds 30 kWth with sCO2 inlet temperatures of 200ºC and particle inlet temperatures up to 440ºC and mass flow rates of 0.2 kg s-1 fluidized by counterflowing gas flow rates of 0.005 kg s-1. Tests at higher particle and sCO2 inlet temperatures (600ºC and 400ºC respectively) are targeted to achieve > 40 kWth with model-predicted overall heat transfer coefficients U > 400 W m-2 K-1.

THE EQUATION OF THE NON-STATIONARY THERMAL CONDUCTIVITY PROBLEM OF THE THERMOMETRICAL DEVICE CONSTRUCTIVE ELEMENT OF WEAPON SYSTEMS AND MILITARY EQUIPMENT

Means of contact thermometry are widely used in various complexes of devices of weapons systems and military equipment. Such means basically involve the use of mechanical contact, in particular, bimetallic temperature transmitters, which are the most widely used thermometer variants in practice. To ensure the proper level of metrological and operational characteristics of bimetallic thermometers, reliable and adequate methods of calculating thermodynamic parameters (distributions of temperature, deformations, stresses caused by force and temperature loads) of the bimetallic package are necessary. The presented work describes an approach to the calculation of non-stationary temperature distribution in a solid-state element of a complex shape, which simulates the operation of a bimetallic thermometer sensor using the contact method. The calculated dependences obtained are the basis for modeling bimetallic thermometers of various structural forms and standard sizes. In order to constructively improve the thermometric system, it is proposed to make bimetallic plates non-one-pieces, but with additional structural inclusions, in the presence of which the temperature distribution and, accordingly, the stress state will approach to uniaxial one. Keywords: differential equations, integration constants, displays of primary heat exchangers, calculation dependencies, information transfer, metrological, operational characteristics, temperature, density, thermal conductivity of the medium.

Study on the influence of circumferential shape on the performance of cross wavy primary surface heat exchanger channel

The primary surface heat exchanger can be described as a compact and highly efficient heat exchanger. In contrast, the cross wavy primary surface heat exchangers are suitable for microturbines. Based on the study of circular cross wavy channel, this study innovatively proposed the triangular cross wavy channel to improve the fluid flow conditions and the rectangular cross wavy channel to increase the overall heat exchange of the channel. The applicability domain of the three types of channels is summarized by numerical simulation. The circular cross wavy channels have the smallest irreversible loss, the triangular cross wavy channels have the highest efficiency and the rectangular channels have the largest total heat transfer. Moreover, the correlations of Nusselt number and friction factor are proposed. The correlations for the Nusselt number and friction coefficient have been validated, and the average absolute errors are 2.71 % and 7.85 % respectively. The results show that the correlation formulas can effectively predict the resistance and heat transfer performance of the cross wavy heat exchange channel.

Conceptual design of a novel megawatt portable nuclear power system by supercritical carbon dioxide brayton cycle coupled with heat pipe cooled reactor

In order to meet realistic requirements for flexible and reliable power supply in special scenarios such as remote areas and deep ocean exploration, a novel megawatt portable nuclear power system called SUPERHERO (SUPERcritical carbon dioxide cycle-HEat pipe ReactOr power system) is proposed in this paper. The system consists of a heat pipe-cooled reactor and a closed supercritical carbon dioxide (S–CO2) Brayton power cycle. Different cycle concepts were compared, and the simple recuperated cycle was adopted for compactness and simplicity of the system. The multi-objective optimization is performed to maximize cycle efficiency and minimize system volume, resulting in optimized parameters for a 1MWe system. By utilizing uranium nitride (UN) modular fuel elements and high heat transfer capacity potassium heat pipes, a compact reactor scheme with 3.13MWt is determined that can operate for 15 years without refueling. The neutronics and thermal analysis of the reactor are carried out, and the results show that the reactor has safety features such as a low peak factor, negative temperature feedback coefficient, sufficient reactivity compensation and control, and anti-failure of single heat pipe. The primary heat exchanger is also designed using the CFD method, and the heat exchange tubes combined with ribbed plates and self-supporting structures are used to enhance heat transfer and ensure structural stability. All these studies outline the general features of SUPERHERO, demonstrating that SUPERHERO has great development potential.

Theoretical and numerical study on new evaluation criteria for longitudinal vortex enhanced heat transfer

The enhancement of heat transfer caused by longitudinal vortex phenomena has been a widely studied topic for a significant period in fluid mechanics and heat transfer. However, despite extensive efforts, the current understanding of longitudinal vortex flow and the involved physical mechanisms leading to enhanced heat transfer remains qualitative in nature. To unveil the physical mechanisms underlying the enhancement of convective heat transfer by longitudinal vortices, further quantitative research and in-depth discussions are necessary. By performing detailed derivations and proofs of the equations, this study aims to further understand the relationship between local vortex variations and heat transfer performance. The results indicate that the presence of longitudinal vortices alters the gradient of the convective term and ultimately leads to enhanced heat transfer performance. Based on the derived results, corresponding metrics have been proposed to quantitatively analyze the degree of heat transfer enhancement due to longitudinal vortices. This proposed quantitative analysis metric has been applied to evaluate the heat transfer performance of a cross-wavy primary surface heat exchanger, validating the reliability of the metrics. The research content and conclusions provide valuable insights for both theoretical investigations and practical engineering applications in the field of enhanced heat transfer.

Numerical simulation and optimization of In-Vessel primary heat exchangers of NHR200-II

NHR200-II is a multipurpose small integral pressurized water reactor. The primary heat exchangers of NHR200-II are in-vessel single-phase heat exchangers. The primary heat exchangers adopted a tube-in-tube bundle design to improve compactness; however, a significant weakness of the tube-in-tube bundle is the nonuniform thermal expansion between the inner and outer tubes owing to the inhomogeneous tube-temperature distribution. To minimize the thermal stress, the inner and outer tube diameters were optimized using numerical simulations. The nonuniform mass flow rates and temperature fields in each channel and tube were calculated using the optimal tube sizes, and the axially averaged temperatures of the inner and outer tubes were also calculated. The present prediction of nonuniform temperature fields can be used as the input to estimate the magnitude of thermal stress in the assessment of the structural integrity of the primary heat exchangers of NHR200-II.

Research on shell-side heat and mass transfer with multi-component in LNG spiral-wound heat exchanger under sloshing conditions

The spiral-wound heat exchanger (SWHE) is the primary low-temperature heat exchanger for large-scale LNG plants due to its high-pressure resistance, compact structure, and high heat exchange efficiency. This paper studied the shell-side heat and mass transfer characteristics of vapor-liquid two-phase mixed refrigerants in an SWHE by combining a multi-component model in FLUENT software with a customized multicomponent mass transfer model. Besides, the mathematical model under the sloshing condition was obtained through mathematical derivation, and the corresponding UDF code was loaded into FLUENT as the momentum source term. The results under the sloshing conditions were compared with the relevant parameters under the steady-state condition. The shell-side heat and mass transfer characteristics of the SWHE were investigated by adjusting the component ratio and other working conditions. It was found that the sloshing conditions enhance the heat transfer performance and sometimes have insignificant effects. The sloshing condition is beneficial to reduce the flow resistance. The comprehensive performance of multi-component refrigerants has been improved and the improvement is more significant under sloshing conditions, considering both the heat transfer and pressure drop. These results will provide theoretical support for the research and design of multi-component heat and mass transfer enhancement of LNG SWHE under ocean sloshing conditions.

Rational design process for gas turbine exhaust to supercritical CO2 waste heat recovery heat exchanger using topology optimization

Advances in additive manufacturing (AM) technologies and topology optimization methodologies are enabling sophisticated novel designs for heat exchanger performance. These tools have been demonstrated for development of high-performance heat sinks considering local or component-level performance factors (e.g., heat transfer per volume). To leverage such capabilities in larger-scale energy systems, structured design methodologies are needed that consider system-level factors, such as production cost, cycle-level efficiency, and operational constraints. This study seeks to develop and assess a rational approach for designing thermo-economically optimal heat exchangers for such applications. The methodology is illustrated through development of the Primary Heat Exchanger (PHX) for a supercritical carbon dioxide (sCO2) power cycle recovering exhaust heat from a 6 MW-scale natural gas turbine. The proposed approach begins with a detailed thermodynamic cycle model, which is then extended to account for techno-economics. Next, an optimal PHX heat transfer capacity target is identified, and a high-level geometry is selected based on operating characteristics. This geometry is then divided into repeating 2D prismatic unit cells, for which topology optimization is applied to identify high-performance heat transfer geometries. A key aspect of this process is that the unit cell geometries are optimized using the total PHX mass as the objective function, which represents a surrogate for production cost. This leads to distinct designs compared with approaches that optimize local heat transfer and flow resistance factors. A second topology-optimized design is developed using a representative local thermal-fluid performance objective function and is found to require 1.6× the mass of the design generated with the system-level techno-economic objective for the same unit cell size. Conventional-type PHX designs with simple longitudinally finned tubes are developed for comparison, and are found to require total masses 1.5× or greater than the design obtained with the proposed process. Integrating this approach with detailed additive manufacturing costing models and experimentally validated fabrication constraints can yield a streamlined workflow for HX design for future energy systems.

System Thermal-Hydraulics Model for Fluoride Salt-Cooled Reactor Based on Small Modular Advanced High Temperature Reactor (SmAHTR) Design Concept

Abstract A system thermal-hydraulics model for a fluoride-salt-cooled high-temperature reactor (FHR) based on the small modular advanced high-temperature reactor (SmAHTR) design concept is developed, using RELAP5-3D. The SmAHTR components modeled in the simulations include the reactor core, lower plenum, upper plenum, top plenum, three primary heat exchangers (PHXs) equipped with three primary pumps, and three director reactor auxiliary cooling system (DRACS) equipped with three fluid diodes. Flows through the reactor core are represented by 19 individual fuel channels, one reflector-hole channel, and one downcomer channel. In each of the 19 SmAHTR fuel block channels, the fuel elements are modeled in five groups using five heat structures, each with their corresponding power level. The total reactor power is 125 MWth. Using representative core power distributions for the SmAHTR at beginning-of-cycle (BOC) and at end-of-cycle (EOC), two steady-state system thermal-hydraulic model simulations with RELAP5-3D were performed using a nominal pressure drop loss factor of 1.5 for all nine junctions in each of the 19 fuel channels modeled. Exit coolant temperatures ranged from 688 °C to 739 °C (BOC) and from 696 °C to 721 °C (EOC), while peak fuel centerline temperatures in the highest power block were 1249 °C (BOC) and 1029 °C (EOC). By adjusting the loss factors to modify coolant flow rates in each channel, a more uniform exit coolant temperature was possible, ranging from 701 °C to 709 °C (BOC) and 698 °C to 714 °C (EOC), while peak fuel centerline temperatures were reduced to 1204 °C (BOC) and 988 °C (EOC), giving results more consistent with earlier studies of the SmAHTR.