Особенности проектирования высокотемпературных пластинчатых теплообменников для малоразмерных газотурбинных двигателей

The first patent for a plate heat exchanger was granted in 1878 to Albretch Dracke, a German inventor. The commercial embodiment of these equipments has become available in 1923. However, the plate heat exchanger development race began in the 1930's and these gasketed plate and frame heat exchangers were mainly used as pasteurizers (e.g. for milk and beer). Industrial plate heat exchangers were introduced in the 1950's and initially they were converted dairy models. Brazed plate heat exchangers were developed in the late 1970's. However, copper brazed units did not start selling until the early 80's. Nickel brazing came to market around ten years later, since copper presents compatibility problems with some streams (e.g. ammonia). All-welded and semi-welded (laser weld) plate heat exchangers were developed during the 1980's and early 90's. Shell and plate heat exchangers were recently introduced in the market and can withstand relatively high pressures and temperatures, as the shell and tube does. The fusion bonded plate heat exchangers (100% stainless steel) are a technology from the 21 st century, these equipments being more durable than brazed plate heat exchangers. The plates are the most important elements from the different plate heat exchangers mentioned above. This paper initially introduces the gasketed plate and frame heat exchanger and common chevron-type plates. Resorting to computer fluid dynamics techniques, the complex 3D flow in cross-corrugated chevron-type plate heat exchanger passages is visualized. Recent patents related with the plates from different plate heat exchangers are then outlined.

Transient response of multi-pass plate heat exchangers considering the effect of flow maldistribution

The Maisotsenko Open Cycle combines the thermodynamic processes of heat exchange and evaporative cooling in a unique indirect evaporative cooler resulting in product temperatures that approach the dew point temperature, (not the wet bulb temperature) of the working gas. It is an open thermodynamic cycle utilizing several thermodynamic processes that cools a product fluid with a liquid evaporating into a gas, generally water evaporating into air from the atmosphere and returns it to the atmosphere. It is a new cycle as no other cycle can be diagramed in the same way on the psychrometric chart of a gas. In a gas turbine, the gas is air and evaporate is water. An atmospheric pressure heat and mass exchanger operating with the Maisotsenko Cycle can be used to cool compressor inlet air below the wet bulb temperature. In a high-pressure heat and mass exchanger the cycle can create a compressed air saturator using heat from the turbine exhaust gases and also cools water for heat recovery in a compressor inter-cooler. The same saturator will humidify and/or superheat the compressed air before entering a combustor to the amount desired. From a practical stand point the limit of humidification of the compressed air is the amount of heat available at a temperature above its dew point temperature from the exhaust gas and/or intercompressor coolers. The amount of superheating or humidifying of the compressed air is easily controlled and changed during operation allowing added power, or greater efficiency, (60% overall thermal efficiency) quickly and easily. The equipment uses existing shell and tube heat exchanger or plate heat exchangers technologies. There are many other benefits ranging from lower NOx to greatly reduced equipment cost compared to any other power cycle enhancement systems.

Thermal-hydraulic performance investigation of an aluminium plate heat exchanger and a 3D-printed polymer plate heat exchanger

The need for compact heat exchangers has led to the development of many types of surfaces that enhance the rate of heat transfer, among them the matrix heat exchangers. These heat exchangers consist of a series of perforated plates mutually separated and sealed by spacers. The goal of this research was to investigate the heat transfer process of matrix heat exchangers on the air side, at the close to ambient conditions. The research was conducted in two directions ? experimental research and CFD research. The experimental investigation was carried out over a perforated plate package with the porosity of 25.6%. The air/water matrix heat exchanger was heated by hot water and was installed in an experimental chamber at which entrance was a fan with the variable flow rate and heated by hot water. The thermocouples were attached to the surface of the perforated plate at the upwind and downwind sides, as well as at the inlet and the outlet of the chamber. During each experiment, the thermocouple readings and the air and water-flow and temperatures were recorded. In the numerical part of the research, the matrix heat exchangers with different plate porosity from 10 to 50% were investigated. The results of the numerical simulations were validated against the experimental results. On the basis of the experimental and numerical results, equations for heat transfer as the function of Reynolds number and geometrical parameters was established.

Investigative research on the heat exchangers with triply periodic minimal surface structures under two hybrid methods

Although inter-compressor cooling has been investigated in the past, it is a completely new way of transferring energy to the hydrogen fuel at this point. High temperature differences from 30 K on the coolant side to more than 300 K after the booster compressor allow for smaller heat exchangers. Comparatively low Mach numbers lead to low pressure losses on the core flow. However, the modeling methods for this type of heat exchanger vary a lot from simple energy balance methods to 3D-CFD. During performance calculations a 3D-CFD is not feasible and more simple methods as the Number of Transfer Units suffer from uncertainties especially during off-design calculation. This paper suggests a conditioning system and a scalable performance map for hydrogen conditioners to be used as “inter compressor cooling” heat exchangers during cycle analysis. A tool for the calculation of heat exchangers in aviation with a higher lever of detail is used to design a tube bundle heat exchanger and create the performance map. A concept for the integration of the heat exchanger in the core engine is presented using 8 stacks distributed around the circumference. For a given geometry, errors in transferred heat below 1 % are achieved across the entire operating range of the engine. A 15 % scaling in effectiveness results in an error of only 3 % at the most loaded operating point. First conducted studies indicate to design an engine for the highest possible fuel temperature while using the least amount of air. This achieves the lowers thrust specific fuel consumption. The direct use of hydrogen as a coolant can lead to problems with icing due to wall temperatures in the heat exchanger matrix being below 0 °C. In addition, there are additional challenges with the safety of such a system. A completely different option for hydrogen conditioning is presented. This is the use of a full electrical conditioning.

The manufacturing of plate heat exchangers is much more difficult than that of making traditional heat exchangers. The demand of increased corrosion resistance, avoiding Cu ion contamination, resisting to high-temperature resulting from various applied environments makes the traditional Cu brazed 316 stainless steel (316SS) plate heat exchanger fail to satisfy certain applications. Corrosion-resistant brazed 316SS plate heat exchangers are successfully developed using two commercially available Ni-based brazing foils, and they are valuable for industrial applications.

A general solution for one-dimensional multistream heat exchangers and their networks

Effect of silica dioxide particles on the evolution of biofouling by Bacillus subtilis in plate heat exchangers relevant to a heat pump system used with treated sewage

Performance enhancement of cabinet cooling system by utilizing cross-flow plate heat exchanger

An advanced Grid Diagram for heat exchanger network retrofit with detailed plate heat exchanger design

Industrial burners provide process heat for a wide range of applications including cogeneration power production. In such applications a (typically) natural gas fired stationary turbine powers an electric generator and indirectly powers a heat recover steam generator (HRSG). The HRSG steam cycle operates by reclaiming the residual thermal energy of the gas turbine exhaust (GTE) flow. Burners are used to reheat the GTE and increase plant capacity during peak demand periods. CFD modeling is used in the design of burner systems for HRSG applications. GTE flow exiting the turbine unit is passed through a diffuser and then expanded into ductwork where the steam system heat exchangers are located. The expansion of the GTE flow from the turbine diffuser to the full cross section of the ductwork is usually severe and creates an uneven flow distribution. Flow correcting structure may be needed to distribute the flow depending upon the severity of the duct expansion. CFD modeling is used to predict the flow distribution of the GTE and guide the design of any necessary flow correcting structure. Burners are typically installed in an array upstream of the application heat exchanger inlet. CFD combustion, heat transfer, and flow analysis is employed in the burner system design process to locate the burner array, determine any necessary flow baffling, and to ensure and provide a uniform thermal distribution at the downstream heat exchanger inlet. Excessive thermal variation in the GTE flow entering the heat exchanger results in large temperature gradients that can lead to thermal cracking and fatigue of the heat exchanger surfaces. CFD modeling is used to ensure that the burner system design produces a uniform flow and temperature distribution at the heat exchanger inlet region downstream of the burners. This report presents a case study of a CFD flow, heat-transfer, and combustion analysis for a typical HRSG burner application. Two CFD models were constructed for the analysis. The first model included the coupled effects of flow, heat transfer, and combustion for the entire HRSG model volume, but excluded the effects of thermal radiation. The second model included a sub-domain of the HRSG volume near the burner and included the additional effects of thermal radiation, both surface radiation and the effects of the radiatively participating flue gas. Radiative effects were included in the second model by employing the Discrete Transfer Method. Results of the study showed the significant role thermal radiative heat transfer had on the resulting temperature predictions downstream of the flame zone.

The performance of a plate heat exchanger (PHE), in comparison with the conventional shell and tube types, through a trade-off analysis of energy cost and capital cost resulting from different temperature approaches in the cross-exchanger of a solvent-based CO2 capture process, was evaluated. The aim was to examine the cost reduction and CO2 emission reduction potentials of the different heat exchangers. Each specific heat exchanger type was assumed for the cross-exchanger, the lean amine cooler and the cooler to cool the direct contact cooler’s circulation water. The study was conducted for flue gases from a natural-gas combined-cycle power plant and the Brevik cement plant in Norway. The standard and the lean vapour compression CO2 absorption configurations were used for the study. The PHE outperformed the fixed tube sheet shell and tube heat exchanger (FTS-STHX) and the other STHXs economically and in emissions reduction. The optimal minimum temperature approach for the PHE cases based on CO2 avoided cost were achieved at 4 °C to 7 °C. This is where the energy consumption and indirect emissions are relatively low. The lean vapour compression CO2 capture process with optimum PHE achieved a 16% reduction in CO2 avoided cost in the cement plant process. When the available excess heat for the production of steam for 50% CO2 capture was considered together with the optimum PHE case of the lean vapour compression process, a cost reduction of about 34% was estimated. That is compared to a standard capture process with FTS-STHX without consideration of the excess heat. This highlights the importance of the waste heat at the Norcem cement plant. This study recommends the use of plate heat exchangers for the cross-heat exchanger (at 4–7 °C), lean amine cooler and the DCC unit’s circulation water cooler. To achieve the best possible CO2 capture process economically and in respect of emissions reduction, it is imperative to perform energy cost and capital cost trade-off analysis based on different minimum temperature approaches.

A Thermal-hydraulic assessment of condensing tube bank heat exchangers for heat and water recovery from flue gas