Expanded Microchannel Heat Exchanger: Finite Difference Modeling

A finite difference model of a heat exchanger (HX) considered maldistribution, axial conduction, heat leak, and the edge effect, all of which are needed to model a high effectiveness HX. An HX prototype was developed, and channel height data were obtained using a computerized tomography (CT) scan from previous work along with experimental results. This study used the core geometry data to model results with the finite difference model, and compared the modeled and experimental results to help improve the expanded microchannel HX (EMHX) prototype design. The root mean square (RMS) error was 3.8%. Manifold geometries were not put into the model because the data were not available, so impacts of the manifold were investigated by varying the temperature conditions at the inlet and exit of the core. Previous studies have not considered the influence of heat transfer in the manifold on the HX effectiveness when maldistribution is present. With no flow maldistribution, manifold heat transfer increases overall effectiveness roughly as would be expected by the greater heat transfer area in the manifolds. Manifold heat transfer coupled with flow maldistribution for the prototype, however, causes a decrease in the effectiveness at high flow rate, and an increase in effectiveness at low flow rate.

On the Use of Dual Cell Density Monoliths

Monolith-type substrates are extensively used in automotive catalytic converters and have gained popularity in several other industrial processes. Despite their advantages over traditional unstructured catalysts, such as large surface area and low pressure drop, novel monolith configurations have not been investigated in depth. In this paper, we use a detailed computational model at the reactor scale, which considers entrance length, turbulence dissipation and internal diffusion limitations, to investigate the impact of using a dual cell substrate on conversion efficiency, pressure drop, and flow distribution. The substrate is divided into two concentric regions, one at its core and one at its periphery, and a different cell density is given to each part. According to the results, a difference of 40% in apparent permeability is sufficient to lead to a large flow maldistribution, which impacts conversion efficiency and pressure drop. The two mentioned variables show a positive or negative correlation depending on what part of the substrate—core or ring—has the highest permeability. This and other results contribute relevant evidence for further monolith optimization.

Full-Field Comparison of MRV and CFD of Gas Flow through Regular Catalytic Monolithic Structures

Understanding the influence of gas flow maldistribution in honeycombs can be beneficial for the process design in various technical applications. Although recent studies have investigated the effect of maldistribution by comparing the results of numerical simulations with experimental measurements, an exhaustive 3D full-field comparison is still lacking. Such full-field comparisons are required to identify and eliminate possible limitations of numerical and experimental tools. For that purpose, spatially resolved flow patterns were simulated by computational fluid dynamics (CFD) and measured experimentally by non-invasive NMR velocimetry (MRV). While the latter might suffer from a misinterpretation of artefacts, the reliability of CFD is linked to correctly chosen boundary conditions. Here, a full-field numerical and experimental analysis of the gas flow within catalytic honeycombs is presented. The velocity field of thermally polarized methane gas was measured in a regular 3D-printed honeycomb and a commercial monolith using an optimized MRV pulse sequence to enhance the obtained signal-to-noise ratio. A second pulse sequence was used to show local flow propagators along the axial and radial direction of the honeycomb to quantify the contribution of diffusion to mass transport. A quantitative comparison of the axially averaged convective flow as determined by MRV and CFD shows a very good matching with an agreement of ±5% and 10% for printed and commercial samples, respectively. The impact of maldistribution on the gas flow pattern can be observed in both simulation and experiments, confirming the existence of an entrance effect. Gas displacement measurements, however, revealed that diffusive interchannel transport can also contribute to maldistribution, as was shown for the commercial sample. The good agreement between the simulation and experiments underpins the reliability of both methods for studying gas hydrodynamics within opaque monolith structures.

Sub-channel analysis of a hexagonal sub-assembly: Influence of blockage and axial power distribution on critical heat flux

Study of thermal hydraulics of a hexagonal sub-assembly is essential to ensure safe operation of liquid metal cooled fast reactors. Identifying the dryout location in fuel sub-assembly (FSA) is a precursor to the determination of safe Critical Heat Flux (CHF) margins. In this study, a sub-channel analysis code coupled with a film thickness model is employed to predict the CHF location in a hexagonal sub-assembly. A simple post-CHF heat transfer model is proposed and validated against the experimental data. The nature of flow resistance changes and operating conditions would significantly influence the occurrence of CHF. To this end, the effect of blockage (0.0 ≤ b ≤ 0.3) and axial power distribution (APD) on CHF is systematically investigated in a hexagonal sub-assembly. It was observed that, the presence of blockage causes coolant flow maldistribution which results in an early occurrence of CHF for higher mass flux (G > 1500 kgm−2s−1) and lower inlet subcooling (ΔTsub ≤ 30 K) conditions for b = 0.3. Furthermore, a comparative study of uniform and sinusoidal heat flux distributions are performed. It was noticed that sinusoidal APD causes early occurrence of CHF compared to uniform APD.