Investigation of Printed Circuit Heat Exchangers for VHTRs

2008 ◽  
Author(s):  
Sai K. Mylavarapu ◽  
Xiaodong Sun ◽  
Justin Figley ◽  
Noah J. Needler ◽  
Richard N. Christensen
Keyword(s):  
High Temperature ◽  
Heat Exchangers ◽  
High Efficiency ◽  
Operating Conditions ◽  
Test Facility ◽  
Dynamics Modeling ◽  
Alloy 617 ◽  
Printed Circuit ◽  
High Temperature Materials ◽  
System Pressure

Very High Temperature Reactors (VHTRs) require high temperature (900–950 °C), high integrity, and high efficiency heat exchangers during normal and off-normal conditions. A class of compact heat exchangers, namely, the Printed Circuit Heat Exchangers (PCHEs), made of high temperature materials, found to have the above characteristics, are being increasingly pursued for heavy duty applications. A high-temperature helium experimental test facility, primarily aimed at investigating the heat transfer and pressure drop characteristics of the PCHEs, was designed and is being built at the Ohio State University. The test facility was designed for a maximum operating temperature and pressure of 900 °C and 3 MPa, respectively. Owing to the high operating conditions, a detailed investigation on various high temperature materials was carried out to aid in the design of the test facility and the heat exchangers. The study showed that alloy 617 is the leading candidate material for high temperature heat exchangers. Two PCHEs, each having 10 hot and 10 cold plates with 12 channels in each plate, are currently being fabricated from alloy 617 plates and will be tested once the test facility is constructed. To supplement the experiments, computational fluid dynamics modeling of a simplified PCHE model is being performed and the results for three flow rate cases of 15, 40, and 90 kg/h and a system pressure of 3 MPa are discussed. In summary, this paper focuses on the study of the high-temperature materials, the design of the helium test facility, the design and fabrication of the PCHEs, and the computational modeling of a simplified PCHE model.

Investigation of High-Temperature Printed Circuit Heat Exchangers for Very High Temperature Reactors

2009 ◽  
Vol 131 (6) ◽  
Author(s):  
Sai Mylavarapu ◽  
Xiaodong Sun ◽  
Justin Figley ◽  
Noah Needler ◽  
Richard Christensen
Keyword(s):  
High Temperature ◽  
Heat Exchangers ◽  
Operating Conditions ◽  
Test Facility ◽  
State University ◽  
Printed Circuit ◽  
High Temperature Materials ◽  
System Pressure ◽  
High Temperature Reactors ◽  
Very High

Very high-temperature reactors require high-temperature (900–950°C) and high-integrity heat exchangers with high effectiveness during normal and off-normal conditions. A class of compact heat exchangers, namely, the printed circuit heat exchangers (PCHEs), made of high-temperature materials and found to have these above characteristics, are being increasingly pursued for heavy duty applications. A high-temperature helium test facility, primarily aimed at investigating the heat transfer and pressure drop characteristics of the PCHEs, was designed and is being built at Ohio State University. The test facility was designed to facilitate operation at temperatures and pressures up to 900°C and 3 MPa, respectively. Owing to the high operating conditions, a detailed investigation on various high-temperature materials was carried out to aid in the design of the test facility and the heat exchangers. The study showed that alloys 617 and 230 are the leading candidate materials for high-temperature heat exchangers. Two PCHEs, each having 10 hot plates and 10 cold plates, with 12 channels in each plate, were fabricated from alloy 617 plates and will be tested once the test facility is constructed. Simultaneously, computational fluid dynamics calculations have been performed on a simplified PCHE model, and the results for three flow rate cases of 15, 40, and 80 kg/h at a system pressure of 3 MPa are discussed. In summary, this paper focuses on the study of the high-temperature materials, the design of the helium test facility, the design and fabrication of the PCHEs, and the computational modeling of a simplified PCHE model.

High Efficiency SOFC Power Cycles With Indirect Natural Gas Reforming and CO2 Capture

2015 ◽  
Vol 12 (2) ◽  
Author(s):  
Stefano Campanari ◽  
Matteo Gazzani
Keyword(s):  
High Temperature ◽  
Natural Gas ◽  
Gas Turbine ◽  
Co2 Capture ◽  
Heat Exchangers ◽  
High Efficiency ◽  
Power Production ◽  
Operating Conditions ◽  
Power Cycles ◽  
Power Cycle

Driven by the search for the highest theoretical efficiency, several studies have investigated in the last years the adoption of fuel cells (FCs) in the field of power production from natural gas with CO2 capture. Most of the proposed power cycles rely on high temperature FCs, namely, solid oxide FCs (SOFCs) and molten carbonate FCs (MCFCs), based on the concept of hybrid FC plus gas turbine cycles. Accordingly, high temperature FCs are integrated with a simple or modified Brayton cycle. As far as SOFCs are concerned, CO2 can be separated downstream the FC via a range of available technologies, e.g., chemical or physical separation processes, oxy-combustion, and cryogenic methods. Following a literature review on promising plant configurations, this work investigates the potential of adopting an external natural gas conversion section with respect to the plant efficiency. As a reference plant, we considered a power cycle proposed by Adams and Barton (2010, “High-Efficiency Power Production From Natural Gas With Carbon Capture,” J. Power Sources, 195(7), pp. 1971–1983), whose performance is the highest found in literature for SOFC-based power cycles, with 82% LHV electrical efficiency. It is based on a prereforming concept where fuel is reformed ahead the SOFC, which thus works with a high hydrogen content fuel. After reproducing the power cycle with the ideal assumptions proposed by the original authors, as second step, the simulations were focused on revising the power cycle, implementing a complete set of assumptions about component losses and more conservative operating conditions about FC voltage, heat exchangers minimum temperature differences (which were previously neglected), maximum steam temperature (set according to heat recovery steam generator (HRSG) practice), turbomachinery efficiency, component pressure losses, and other adjustments. The simulation also required to design an appropriate heat exchangers network, which turned out to be very complex, instead of relying on the free allocation of heat transfer among all components. Considering the consequent modifications with respect to the original layout, the net electric efficiency changes to around 63% LHV with nearly complete (95%+) CO2 capture, a still remarkable but less attractive value. On the other hand, the power cycle requires a complicated and demanding heat exchangers network and heavily relies on the SOFC performances, not generating a positive power output from the gas turbine loop. Detailed results are presented in terms of energy and material balances of the proposed cycles. All simulations have been carried out with the proprietary code GS, developed by the GECOS group at Politecnico di Milano.

Thermal hydraulic performance testing of printed circuit heat exchangers in a high-temperature helium test facility

2014 ◽  
Vol 65 (1-2) ◽  
pp. 605-614 ◽  
Author(s):  
Sai K. Mylavarapu ◽  
Xiaodong Sun ◽  
Richard E. Glosup ◽  
Richard N. Christensen ◽  
Michael W. Patterson
Keyword(s):  
High Temperature ◽  
Heat Exchangers ◽  
Performance Testing ◽  
Hydraulic Performance ◽  
Test Facility ◽  
Printed Circuit

Chromium Activity Measurements in Nickel Based Alloys for Very High Temperature Reactors: Inconel 617, Haynes 230, and Model Alloys

2009 ◽  
Vol 131 (6) ◽  
Author(s):  
Stéphane Gossé ◽  
Thierry Alpettaz ◽  
Sylvie Chatain ◽  
Christine Guéneau
Keyword(s):  
High Temperature ◽  
Heat Exchangers ◽  
Mass Spectrometric ◽  
Operating Conditions ◽  
Pure Substance ◽  
Haynes 230 ◽  
Inconel 617 ◽  
High Temperature Reactor ◽  
High Temperature Reactors ◽  
Very High

The alloys Haynes 230 and Inconel 617 are potential candidates for the intermediate heat exchangers (IHXs) of (very) high temperature reactors ((V)-HTRs). The behavior under corrosion of these alloys by the (V)-HTR coolant (impure helium) is an important selection criterion because it defines the service life of these components. At high temperature, the Haynes 230 is likely to develop a chromium oxide on the surface. This layer protects from the exchanges with the surrounding medium and thus confers certain passivity on metal. At very high temperature, the initial microstructure made up of austenitic grains and coarse intra- and intergranular M6C carbide grains rich in W will evolve. The M6C carbides remain and some M23C6 richer in Cr appear. Then, carbon can reduce the protective oxide layer. The alloy loses its protective coating and can corrode quickly. Experimental investigations were performed on these nickel based alloys under an impure helium flow (Rouillard, F., 2007, “Mécanismes de formation et de destruction de la couche d’oxyde sur un alliage chrominoformeur en milieu HTR,” Ph.D. thesis, Ecole des Mines de Saint-Etienne, France). To predict the surface reactivity of chromium under impure helium, it is necessary to determine its chemical activity in a temperature range close to the operating conditions of the heat exchangers (T≈1273 K). For that, high temperature mass spectrometry measurements coupled to multiple effusion Knudsen cells are carried out on several samples: Haynes 230, Inconel 617, and model alloys 1178, 1181, and 1201. This coupling makes it possible for the thermodynamic equilibrium to be obtained between the vapor phase and the condensed phase of the sample. The measurement of the chromium ionic intensity (I) of the molecular beam resulting from a cell containing an alloy provides the values of partial pressure according to the temperature. This value is compared with that of the pure substance (Cr) at the same temperature. These calculations provide thermodynamic data characteristic of the chromium behavior in these alloys. These activity results call into question those previously measured by Hilpert and Ali-Khan (1978, “Mass Spectrometric Studies of Alloys Proposed for High-Temperature Reactor Systems: I. Alloy IN-643,” J. Nucl. Mater., 78, pp. 265–271; 1979, “Mass Spectrometric Studies of Alloys Proposed for High-Temperature Reactor Systems: II. Inconel Alloy 617 and Nimomic Alloy PE 13,” J. Nucl. Mater., 80, pp. 126–131), largely used in the literature.

scholarly journals Externally Fired Combined Cycles (EFCC): Part B — Alternative Configurations and Cost Projections

1996 ◽  
Author(s):  
Stefano Consonni ◽  
Ennio Macchi
Keyword(s):  
High Temperature ◽  
Heat Exchangers ◽  
Gas Turbines ◽  
High Efficiency ◽  
Complete Combustion ◽  
Economic Issues ◽  
Temperature Heat ◽  
Combined Cycles ◽  
Power Outputs ◽  
The Cost

Externally Fired Combined Cycles (EFCC) constitute one of the options allowing the use of “dirty” fuels like coal, biomass or waste in conjunction with modern, high efficiency gas turbines. This two-part paper discusses thermodynamic, technological and economic issues crucial to the successful realization of EFCCs. Part B discusses the cycle arrangement, its implications for the design and the cost of the high temperature heat exchangers, the effects of scale and the economic prospects. An “enhanced” configuration whereby the excess air sent to the combustor is limited to the minimum required for complete combustion can reach net LHV efficiencies above 50%, with relatively low high-temperature heat transfer surface requirements. Cost projections are hindered by the uncertainty on the cost of the high temperature heat exchangers. Estimates based on published and proprietary data collected by the authors indicate that EFCCs should be cost-competitive with IGCCs, especially at medium-low power outputs.

scholarly journals Development of a Multi-Loop Flow and Heat Transfer Facility for Advanced Nuclear Reactor Thermal Hydraulic and Hybrid Energy System Studies

2014 ◽  
Author(s):  
James E. O’Brien ◽  
Piyush Sabharwall ◽  
SuJong Yoon
Keyword(s):  
High Temperature ◽  
Nuclear Reactor ◽  
National Laboratory ◽  
Energy System ◽  
Operating Conditions ◽  
Test Facility ◽  
Flow Loop ◽  
Hybrid Energy ◽  
Conceptual Design Phase ◽  
Intermediate Heat Exchanger

A new high-temperature multi-fluid, multi-loop test facility for advanced nuclear applications is under development at the Idaho National Laboratory. The facility will include three flow loops: high-temperature helium, molten salt, and steam/water. Molten salts have been identified as excellent candidate heat transport fluids for primary or secondary coolant loops, supporting advanced high temperature and small modular reactors (SMRs). Details of some of the design aspects and challenges of this facility, which is currently in the conceptual design phase, are discussed. A preliminary design configuration will be presented, with the required characteristics of the various components. The loop will utilize advanced high-temperature compact printed-circuit heat exchangers (PCHEs) operating at prototypic intermediate heat exchanger (IHX) conditions. The initial configuration will include a high-temperature (750°C), high-pressure (7 MPa) helium loop thermally integrated with a molten fluoride salt (KF-ZrF4) flow loop operating at low pressure (0.2 MPa) at a temperature of ∼450°C. Experiment design challenges include identification of suitable materials and components that will withstand the required loop operating conditions. Corrosion and high temperature creep behavior are major considerations. The facility will include a thermal energy storage capability designed to support scaled process heat delivery for a variety of hybrid energy systems and grid stabilization strategies. Experimental results obtained from this research will also provide important data for code verification and validation (V&V) related to these systems.

scholarly journals Problems of sodium using in pulsating heat pipe made from fused silica

2018 ◽  
Vol 207 ◽  
pp. 04004
Author(s):  
Radovan Nosek ◽  
Tatiana Liptáková ◽  
Libor Trško ◽  
Zuzana Kolková ◽  
Milan Malcho ◽  
...  
Keyword(s):  
High Temperature ◽  
Heat Pipe ◽  
Alkali Metals ◽  
High Efficiency ◽  
Fused Silica ◽  
Operating Conditions ◽  
Liquid Sodium ◽  
Working Fluid ◽  
Pulsating Heat Pipe ◽  
High Temperature Reaction

You Heat pipe is a high efficiency heat transfer element, depends on the evaporation, condensation and circulation of inside working fluid. The working fluid of a high temperature pulsating heat pipe is generally alkali metals, and sodium heat pipe can operate in range of 500-1100°C. In order to investigate terminal velocity of working fluid, the glass pulsating heat pipe was produced for experimental purposes. The experiment was carried out, in order to simulate real operating conditions in range of 500-1100°C. Sudden boiling of liquid sodium (b.p. = 883°C at 1 atm) inside the all quartz-made heat pipe results in high-temperature reaction of sodium vapour with the inner wall surface. The reaction became more aggressive with increasing vapour temperature and resulted in heat pipe explosion. The evaluation of damage character is analysed in this paper.

scholarly journals The Component Test Facility: A National User Facility for Testing of High Temperature Gas-Cooled Reactor (HTGR) Components and Systems

2008 ◽  
Author(s):  
Vondell J. Balls ◽  
David S. Duncan ◽  
Stephanie L. Austad
Keyword(s):  
High Temperature ◽  
Large Scale ◽  
High Efficiency ◽  
Scale Effects ◽  
Nuclear Plant ◽  
Department Of Energy ◽  
Test Facility ◽  
Component Test ◽  
User Facility ◽  
High Temperature Gas

The Next Generation Nuclear Plant (NGNP) and other High-Temperature Gas-cooled Reactor (HTGR) Projects require research, development, design, construction, and operation of a nuclear plant intended for both high-efficiency electricity production and high-temperature industrial applications, including hydrogen production. During the life cycle stages of an HTGR, plant systems, structures and components (SSCs) will be developed to support this reactor technology. To mitigate technical, schedule, and project risk associated with development of these SSCs, a large-scale test facility is required to support design verification and qualification prior to operational implementation. As a full-scale helium test facility, the Component Test facility (CTF) will provide prototype testing and qualification of heat transfer system components (e.g., Intermediate Heat Exchanger, valves, hot gas ducts), reactor internals, and hydrogen generation processing. It will perform confirmation tests for large-scale effects, validate component performance requirements, perform transient effects tests, and provide production demonstration of hydrogen and other high-temperature applications. Sponsored wholly or in part by the U.S. Department of Energy, the CTF will support NGNP and will also act as a National User Facility to support worldwide development of High-Temperature Gas-cooled Reactor technologies.

Failure Mode Effects Analysis for Section III, Division 5 Class A, High Temperature Service of a Printed Circuit Heat Exchanger

2020 ◽  
Author(s):  
Ian Jentz ◽  
Suzanne McKillop ◽  
Robert Keating
Keyword(s):  
High Temperature ◽  
Failure Mode ◽  
Heat Exchangers ◽  
Failure Modes ◽  
Department Of Energy ◽  
Compact Heat Exchangers ◽  
Printed Circuit ◽  
Mode Effects ◽  
Class A ◽  
Asme Code

Abstract The mission of the U.S. Department of Energy (DOE), Office of Nuclear Energy is to advance nuclear power in order to meet the nation’s energy, environmental, and energy security needs. Advanced high temperature reactor systems will require compact heat exchangers (CHX) for the next generation of nuclear reactor plant designs. A necessary step for achieving this objective is to ensure that the ASME Boiler and Pressure Vessel Code, Section III, Division 5 has rules for the construction of CHXs for nuclear service. Given their high thermal efficiency and compactness, expanding the use of Alloy 800H diffusion bonded Printed Circuit Heat Exchangers (PCHEs) beyond their current application in Section VIII, Division 1 to the high temperature nuclear applications is of interest. The research being completed under the Department of Energy project is focused on preparing a draft Code Case for consideration by the ASME Code Committees for high temperature nuclear components which must meet the requirements of Section III, Division 5, Subsection HB (Class A), Subpart B. Acceptance of a Code Case by the ASME Code Committees to use PCHEs in nuclear service requires a broad understanding of PCHE failure mechanisms. At the highest level, the ASME Code requirements prevent failures of structures and pressure boundaries. Historically, the approach is a process of understanding the known failure modes, such as overload failures, plastic collapse, progressive distortion (ratcheting) and fatigue, and then establishing rules for construction to preclude those failure modes in components. For Division 5 applications, attention to differential thermal expansion, creep life, and creep-fatigue must also be considered. Failure from these loadings is manifest within PCHEs both within the internal micro-channel geometry, and at substantially larger solid header and nozzle attachments. To address the adequacy of the PCHE, a Failure Mode Effects Analysis (FMEA) has been performed for standard etched channel PCHEs. This FMEA is linked to the proposed rules in the code case for compact heat exchangers in Section III, Division 5 Class A applications. The PCHE FMEA covers all design failures addressed by Section III.

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