Search Results (49)

Printed circuit heat exchangers (PCHE) are ideal for use in very demanding operating conditions. In addition, they are characterized by very high efficiency, which can still be increased. This paper presents new concepts for improving PCHE heat exchangers. The aim of the described work was to evaluate the potential for improving the performance of printed circuit heat exchangers by incorporating open-cell metal foam as the heat exchanger packing material. The evaluation was conducted based on the results of numerical simulation of supercritical carbon dioxide cooling flowing through printed circuit heat exchanger channels filled with 40 PPI copper foam with 90% porosity. A unit periodic region of the heat exchanger comprising two adjacent straight channels for cold and hot fluid was analyzed. The channels had a semicircular cross-section and a length of 200 mm. Studies were conducted for three different channel diameters—2, 3, and 4 mm. The range of mass flux variations for cold fluid (water) and hot fluid (sCO₂) were 300–1500 kg/(m²·s) and 200–800 kg/(m²·s), respectively. It was found that in channels filled with metal foam, carbon dioxide cooling is characterized by a higher heat transfer coefficient than in channels without metal foam. In channels of the same diameter, heat flux was 33–63% higher in favor of the channel with metal foam. Thermal effectiveness of the heat exchanger with metal foam can be up to 20% higher than in the case of a heat exchanger without foam. Despite very high pressure drop through channels filled with metal foam, thermal–hydraulic performance can also be higher—even 4.7 in the case of a 2 mm channel. However, both these parameters depend on flow conditions and channel diameter, and under certain conditions may be lower than in a heat exchanger without metal foam. The results of the presented work indicate a new direction for the development of PCHE heat exchangers and confirm that the use of metal foams in the construction of PCHE heat exchangers can contribute to increasing the efficiency and effectiveness of the processes in which they are used. Full article

Printed-circuit heat exchangers (PCHEs) are compact exchangers with exceptional heat-transfer properties that are important for supercritical CO₂ technology. Recalculating the heat transfer under off-design conditions is a common task. Thus, in this paper, traditional and PCHE-specific correlations are analyzed in a conventional, discretized one-dimensional model using the conductance ratio method. The predicted heat transfer is compared with the experimental data of a CO₂–CO₂ heat exchanger with zigzag-type channels and one with s-shaped fin channels under various working conditions. The results demonstrate that all selected heat-transfer correlations predicted the transferred heat within +/−20% using the conventional model. The much simpler conductance ratio method yields better results, with heat transfer within +/−10%, even with conservative inputs to the model. Full article

Molten salt heat exchangers are pivotal components in advanced energy systems, where their high-temperature stability and efficient heat transfer performance are critical for system reliability. This paper provides a comprehensive review of recent advancements in molten salt heat exchanger technology, focusing on their application in nuclear energy, concentrated solar power, and thermal energy storage systems. Key design considerations, including thermophysical properties of molten salts and operational conditions, are analyzed to highlight performance optimization strategies. The review traces the evolution from traditional shell-and-tube heat exchangers to compact designs like printed circuit heat exchangers, emphasizing improvements in heat transfer efficiency and power density. Challenges such as material corrosion, manufacturing complexities, and flow dynamics are critically examined. Furthermore, future research directions are proposed, including the development of high-performance materials, advanced manufacturing techniques, and optimized geometries. This review aims to consolidate dispersed research findings, address technological bottlenecks, and provide a roadmap for the continued development of molten salt heat exchangers in high-temperature energy systems. Full article

While extensive research has focused on improving the efficiency and performance of heat exchangers (HXs), identifying the underlying causes of performance degradation remains equally important. Flow and temperature non-uniformities are among the most critical factors affecting performance, often reducing thermo-hydraulic efficiency by approximately 5–10%. These non-uniformities commonly manifest as thermal inconsistencies, airflow maldistribution, and uneven refrigerant distribution. Researchers have observed a notable performance degradation—up to 27%—due to flow maldistribution. Therefore, a clear understanding of their causes and effects is essential for developing effective mitigation strategies to enhance system performance. Despite the notable progress in this area, few studies have systematically classified the dominant non-uniformities associated with specific HX types. This article presents a two-decade review of the causes, impacts, and mitigation approaches related to non-uniformities across different HX configurations. The primary objective is to identify the most critical form of non-uniformity affecting performance in each category. This review specifically examines plate heat exchangers (PHXs), finned and tube heat exchangers (FTHXs), microchannel heat exchangers (MCHXs), and printed circuit heat exchangers (PCHXs). It also discusses mathematical models designed to account for non-uniformities in HXs. This article concludes by identifying key research gaps and outlining future directions to support the development of more reliable and energy-efficient HXs. Full article

Within the energy sector, the potential to effectively harness the considerable energy present in gas turbine waste heat via an organic Rankine cycle (ORC) could markedly improve overall energy efficiency. This investigation centers on a printed-circuit heat exchanger (PCHE) utilizing cyclopentane as the working fluid. The study employs a combination of experimental techniques and computational fluid dynamics (CFD) simulations to conduct an in-depth analysis of the PCHE’s performance, leading to the successful development of a highly accurate heat-transfer correlation. A thorough comparison of experimental and simulation data is carried out to examine the temperature and pressure distributions within the heat exchanger. The maximum deviation between experimental and correlation-estimated data is within 20% (hot fluid: 15%; cold fluid: 18%). These findings offer essential theoretical insights and practical guidance for optimizing and ensuring the stable operation of waste-heat recovery systems. Full article

This paper proposes two compact, efficient, and lightweight heat exchangers based on triply periodic minimal surfaces (TPMSs). Designed in an annular configuration, the heat exchangers meet the requirements of micro gas turbines for compactness. Two prototypes of Diamond and Gyroid modular TPMS heat exchangers were fabricated using selective laser melting (SLM) with stainless steel. The flow and heat transfer experimental results indicate that, within a Reynolds number range of 200 to 800, the effectiveness of both heat exchangers remained above 0.62, and the average Nusselt numbers of the Diamond and Gyroid structures reached 3.60 and 4.06 times that of the printed circuit heat exchanger (PCHE), respectively. Although both heat exchangers exhibited relatively high friction factors, their overall performance surpassed that of conventional heat exchangers. Additionally, performance comparisons with existing TPMS heat exchangers revealed that smaller lattice sizes contribute to improved volume-based power density, although they result in increased pressure loss. Simulation results indicated that the “merge–split” effect present in both structures enhances heat transfer between the fluid and the wall. Furthermore, the complex channels of the TPMS structures ensure that the fluid maintains strong turbulence intensity throughout the heat exchanger. This study demonstrates that stainless steel TPMS structures can serve as excellent candidates for applications in micro gas turbines. Full article

The PCHE, as an efficient heat exchanger, plays a crucial role in the storage and regasification of LNG. However, among the existing studies, those that integrate this field with deep learning are scarce. Moreover, research on explainability remains insufficient. To address these gaps, this study first constructs a dataset of heat transfer coefficients (h) through numerical simulations. Pearson correlation analysis is employed to screen out the most influential features. In terms of predictive modeling, the study compares five traditional machine learning models alongside deep learning models such as long short-term memory neural networks (LSTMs), gated recurrent units (GRUs), and Transformer. To further enhance prediction accuracy, three attention mechanisms—self-attention mechanism (SA), squeeze-and-excitation mechanism (SE), and local attention mechanism (LA)—are incorporated into the deep learning models. The experimental results demonstrate that the artificial neural network achieves the best performance among the traditional models, with a prediction accuracy for straight-path h reaching 0.891799 (R²). When comparing deep learning models augmented with attention mechanisms against the baseline models, both LSTM–SE in the linear flow channel and Transformer–LA in the hexagonal flow channel exhibit improved prediction accuracy. Notably, in predicting the heat transfer coefficient of the hexagonal channel, the determination coefficient (R²) of the Transformer–LA model reaches 0.9993, indicating excellent prediction performance. Additionally, this study introduces the SHAP interpretable analysis method to elucidate model predictions, revealing the contributions of different features to model outputs. For instance, in a straight flow channel, the hydraulic diameter (Dh) contributes most significantly to the model output, whereas in a hexagonal flow channel, wall temperature (Tinw) and heat flux (Qw) play more prominent roles. In conclusion, this study offers novel insights and methodologies for PCHE performance prediction by leveraging various machine learning and deep learning models enhanced with attention mechanisms and incorporating explainable analysis methods. These findings not only validate the efficacy of machine learning and deep learning in complex heat exchanger modeling but also provide critical theoretical support for engineering optimization. Full article

The supercritical carbon dioxide Brayton cycle has been identified as being applicable in a wide variety of applications, and printed circuit heat exchangers (PCHEs) are widely used in these applications due to their good compactness and high thermal efficiency. A PCHE with hybrid-size unit channels has been proposed and found capable of improving the heat transfer performance, but most results were obtained at non-consistent total volume and mass flow rate. Therefore, given the space constraints of heat exchangers in supercritical CO₂ Brayton cycles, this study investigates the application of standard-size and hybrid-size unit channel configurations under different hot-to-cold fluid thermal resistance ratios while maintaining a fixed total volume and consistent total mass flow rate. The results demonstrate that the hybrid-size unit channel configuration fails to enhance heat transfer. The heat transfer rate per volume exhibits a marginal 5.2% reduction at smaller thermal resistance ratios and a drastic 28.9% degradation at larger thermal resistance ratios. The hybrid-size channel configuration significantly improves the pressure drop per unit length on the hot side, achieving maximum reductions of 80.3% and 79.7% under the two thermal resistance ratios, respectively. The enhancement magnitude on the hot side outweighs the increased pressure drop on the cold side. Simultaneously, the ratio of average heat transfer rate to total pumping power exhibits significant differences between the two channel configurations under varying thermal resistance ratios. Under scenarios with substantial thermal resistance disparities, the hybrid-size unit channel configuration achieves a maximum 356.2% improvement in the ratio compared to the identical-size unit channel configuration, whereas balanced thermal resistance ratios lead to a degradation in overall performance. Full article

Hydrogen fuel cell systems are a viable option for electrified aero engines due to their efficiency and environmental benefits. However, integrating these systems presents challenges, notably in terms of overall system weight and thermal management. Heat exchangers are crucial for the effective thermal management system of electric propulsion systems in commercial electrified aviation. This paper provides a comprehensive review of various heat exchanger types and evaluates their potential applications within these systems. Selection criteria are established based on the specific requirements for air and hydrogen heat exchangers in electrified aircraft. The study highlights the differences in weighting criteria for these two types of heat exchangers and applies a weighted point rating system to assess their performance. Results indicate that extended surface, microchannel, and printed circuit heat exchangers exhibit significant promise for aviation applications. The paper also identifies key design challenges and research needs, particularly in enhancing net heat dissipation, increasing compactness, improving reliability, and ensuring effective integration with aircraft systems. Full article

We propose a non-magnetic transparent heating film based on silver nanowires (Ag-NWs) for application in spin-exchange relaxation-free (SERF) magnetic field measurement devices. To achieve ultra-high sensitivity in atomic magnetometers, the atoms within the alkali metal vapor cell must be maintained in a stable and uniform high-temperature environment. Ag-NWs, as a transparent conductive material with exceptional electrical conductivity, are well suited for this application. By employing high-frequency AC heating, we effectively minimize associated magnetic noise. The experimental results demonstrate that the proposed heating film, utilizing a surface heating method, can achieve temperatures exceeding 140 °C, which is sufficient to vaporize alkali metal atoms. The average magnetic flux coefficient of the heating film is 0.1143 nT/mA. Typically, as the current increases, a larger magnetic field is generated. When integrated with the heating system discussed in this paper, this characteristic can effectively mitigate low-frequency magnetic interference. In comparison with traditional flexible printed circuits (FPC), the Ag-NWs heating film exhibits a more uniform temperature distribution. This magnetically transparent heating film, leveraging Ag-NWs, enhances atomic magnetometry and presents opportunities for use in chip-level gyroscopes, atomic clocks, and various other atomic devices. Full article

In recent years, additive manufacturing has reached the required reliability to effectively compete with standard production techniques of mechanical components. In particular, the geometrical freedom enabled by innovative manufacturing techniques has revolutionized the design trends for compact heat exchangers. Bioinspired structures, such as the gyroid lattice, have relevant mechanical and heat exchange properties for their light weight and increased heat exchange area, which also promotes the turbulent regime of the coolant. This work focuses its attention on the effect of the relevant design parameters of the gyroid lattice on heat exchange performances. A numerical comparative analysis is carried out from the thermal and fluid dynamic points of view to give design guidelines. The results of numerical analyses, performed on cylindrical samples, are compared to the experimental results on the pressure drop. Lattices samples were successfully printed with material extrusion, which is a low-cost and easy-to-use metal AM technology. For each lattice sample, counter pressure, heat exchange, and turbulence intensity ratio are calculated from the numerical point of view and discussed. At the end, the gyroid lattice is proven to be very effective at enhancing the heat exchange in cylindrical pipes. Guidelines are given about the choice of the best lattice, depending on the considered applications. Full article

Helium-xenon (HeXe)-cooled mobile nuclear reactors have promising potential in future low-carbon energy systems. However, there is currently a lack of fast and reliable tools for analyzing the complicated dynamic characteristics of such systems. In this study, we developed a comprehensive dynamic modeling approach for a HeXe-cooled nuclear power system coupled with a closed Brayton cycle (CBC). The system’s key components, including the reactor, printed circuit heat exchanger (PCHE), and turbomachinery, are lumped-modeled to capture their time-varying behavior. A step-solving algorithm that incorporates HeXe mass conservation iteration is designed. The verification results demonstrate that the dynamic program is robust and reliable, with each time step converging within 25 iterations and the HeXe mass remaining within the range of 3.755 ± 0.01 kg throughout the simulation meeting the law of mass conservation. Then, a 1500 s frozen start-up simulation for the coupled system is conducted, in which the CBC is started in the first 500 s by increasing the main shaft speed to 40% of the rated value, and then the reactor is started by inserting external reactivity between 500 and 800 s. Both the dynamic process and the steady-state performance after the start-up are analyzed. The results show that the system achieved a stable electrical output of 5.7 MWe with a thermal efficiency of 32.5%. This study lays a solid foundation for future work aimed at improving the overall efficiency and performance of HeXe-cooled nuclear power systems. Full article

Recently, supercritical CO₂ (S-CO₂) has been extensively applied for the recovery of waste heat from flue gas. Although various cycle configurations have been proposed, existing studies predominantly focus on the steady analysis and optimization of different S-CO₂ structures under design conditions, and there is a noticeable deficiency in off-design research, especially for the innovative S-CO₂ cycles. Thus, in this work aimed at the proposed novel S-CO₂ power cycle, off-design characteristics and corresponding control strategies are investigated for the waste heat recovery. Based on the design parameters of the S-CO₂ cycle, structural dimensions of printed circuit heat exchangers (PCHEs) and shell-and-tube heat exchangers are determined, and design values of turbines and compressors are specified. On this basis, off-design models for these key components are formulated. By manipulating variables such as cooling water inlet temperature, cooling water mass flow rate, flue gas inlet temperature and flue gas mass flow rate, cycle performances of the system are analyzed under off-design conditions. The simulation results show that when the inlet temperature and the mass flow rate of cooling water vary separately, the thermal efficiency both can reach the maximum value of 28.43% at the design point. For the changes in heat source parameters, the optimum point is slightly deviated from the design condition. Amidst the fluctuations in flue gas inlet temperature, the thermal efficiency optimizes to a peak of 28.56% at 530 °C. In the case of variation in the flue gas mass flow rate, the highest thermal efficiency 28.75% can be obtained. Furthermore, to maintain the efficient and stable operation of the S-CO₂ power cycle, the corresponding control strategy of the cooling water mass flow rate is proposed for the cooling water inlet temperature variation. Generally, when the inlet temperature of cooling water increases from 23 °C to 27 °C, the cooling water mass flow should increase from 82.3% to 132.7% of the design value to keep the system running as much as possible at design conditions. Full article

The concentration of residual O₂ in oxy-fuel combustion flue gas needs to be reduced before CO₂ transportation, utilization, or storage. An original application of the printed circuit heat exchanger (PCHE) for catalytic combustion with natural gas (catalytic deoxygenation) is described for reducing the residual O₂ concentration. The PCHE design features multiple adiabatic packed beds with interstage cooling and fuel injection, allowing precise control over the reaction extent and temperature within each reaction stage through the manipulation of fuel and utility flow rates. This work describes the design of a PCHE for methane–oxygen catalytic combustion where the catalyst loading is minimized while reducing the O₂ concentration from 3 vol% to 100 ppmv, considering a maximum adiabatic temperature rise of 50 °C per stage. Each PCHE design differs by the number of reaction stages and its individual bed lengths. As part of the design process, a one-dimensional transient reduced-order reactor model (1D ROM) was developed and compared to temperature and species concentration axial profiles from 3D CFD simulations. The final design consists of five reaction stages and four heat exchanger sections, providing a PCHE length of 1.09 m at a processing rate of 12.3 kg/s flue gas per m³ PCHE. Full article

The gas turbine is a crucial piece of equipment in the energy and power industry. The exhaust gas has a sufficiently high temperature to be recovered for energy cascade use. The supercritical carbon dioxide (S-CO₂) Brayton cycle is an advanced power system that offers benefits in terms of efficiency, volume, and flexibility. It may be utilized for waste heat recovery (WHR) in gas turbines. This study involved the design of a 5 MW S-CO₂ recompression cycle specifically for the purpose of operational control. The dynamic models for the printed circuit heat exchangers, compressors, and turbines were developed. The stability and dynamic behavior of the components were validated. The suggested control strategies entail utilizing the cooling water controller to maintain the compressor inlet temperature above the critical temperature of CO₂ (304.13 K). Additionally, the circulating mass flow rate is regulated to modify the output power, while the exhaust gas flow rate is controlled to ensure that the turbine inlet temperature remains within safe limits. The simulations compare the performance of PI controllers tuned using the SIMC rule and ADRC controllers tuned using the bandwidth method. The findings demonstrated that both controllers are capable of adjusting operating conditions and effectively suppressing fluctuations in the exhaust gas. The ADRC controllers exhibit a superior control performance, resulting in a 55% reduction in settling time under the load-tracking scenario. Full article