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• 1. [Article] Half Array Architecture for Advancing Microchannel Heat Recuperation to Market

  High temperature microchannel heat recuperators (HTμRs) offer an efficient means of improving reactor process thermal efficiency by offering smaller form factors due to increased heat transfer surface ...

  Citation × Citation Citation Abstract Copy Title: Half Array Architecture for Advancing Microchannel Heat Recuperation to Market Author: Brannon, Samuel T. High temperature microchannel heat recuperators (HTμRs) offer an efficient means of improving reactor process thermal efficiency by offering smaller form factors due to increased heat transfer surface area density and volumetric heat transfer rate over traditional heat exchanger designs. To date, HTμRs face cost and reliability challenges. In this work, a HTμR design was developed capable of utilizing high volume manufacturing methods to improve raw material utilization and cost. The design utilizes a microchannel flow insert (MFI) to resist differential pressures within low pressure channels eliminating the need for photochemical machining. The MFIs are placed within a laser-welded microchannel half array which is inserted within a metal housing to establish the counter flow path. Analytical and computational models were developed to guide the structural, thermal and fluidic design of the sub-millimeter MFI for waste heat applications. A forming process was developed for producing the MFIs and experimental investigations were used to validate structural, thermal and fluidic performance. A robust microforming fabrication process was developed capable of providing average MFI heights of 529 μm with 0.5% standard deviation. MFIs were analyzed for out-of-plane compressive stiffness and compressive strength over multiple loading cycles to validate both analytical and finite element models. A finite element model provided a model error of 6.8% for compressive stiffness. The unbonded μPTN design presented yields an 88% decrease in structural panel size compared to macro-pyramidal truss networks for a given loading condition while maintaining similar panel area. Single layer fluid flow experiments were conducted to determine the average Nusselt number and pressure drop in microchannels both with and without an MFI installed. The MFI increased the average Nusselt number by 2.9x due to increased fluid mixing. The pressure drop through the MFI was found to be on average five times higher than the empty channel due to reduced flow cross-section area. The network pressure drop model yielded a percent error at low Reynolds numbers of 5.2%. Subsequently, a 3.5 kW HTμR made of Inconel 625 was designed for waste heat recovery with an inlet temperature of 850°C. A subscale HTμR was fabricated and tested to validate the 3.5 kW design. The sub-scale five layer HTμR was tested with a hot side inlet temperature of 300°C. The sub-scale device performed as expected in terms of effectiveness (4.3% error), duty (4.3% error), and MFI channel pressure drop (-2.6% error). These results were used to scale a 3.5 kW Inconel 625 HTμR with a heat transfer surface area density of 1,633 m²/m³, a volumetric heat transfer coefficient of 2.3 MW/(m³K), and a volumetric heat transfer rate of 32 MW/m³ providing improved results versus high temperature recuperator designs in literature. Title: Half Array Architecture for Advancing Microchannel Heat Recuperation to Market Author: Brannon, Samuel T. High temperature microchannel heat recuperators (HTμRs) offer an efficient means of improving reactor process thermal efficiency by offering smaller form factors due to increased heat transfer surface area density and volumetric heat transfer rate over traditional heat exchanger designs. To date, HTμRs face cost and reliability challenges. In this work, a HTμR design was developed capable of utilizing high volume manufacturing methods to improve raw material utilization and cost. The design utilizes a microchannel flow insert (MFI) to resist differential pressures within low pressure channels eliminating the need for photochemical machining. The MFIs are placed within a laser-welded microchannel half array which is inserted within a metal housing to establish the counter flow path. Analytical and computational models were developed to guide the structural, thermal and fluidic design of the sub-millimeter MFI for waste heat applications. A forming process was developed for producing the MFIs and experimental investigations were used to validate structural, thermal and fluidic performance. A robust microforming fabrication process was developed capable of providing average MFI heights of 529 μm with 0.5% standard deviation. MFIs were analyzed for out-of-plane compressive stiffness and compressive strength over multiple loading cycles to validate both analytical and finite element models. A finite element model provided a model error of 6.8% for compressive stiffness. The unbonded μPTN design presented yields an 88% decrease in structural panel size compared to macro-pyramidal truss networks for a given loading condition while maintaining similar panel area. Single layer fluid flow experiments were conducted to determine the average Nusselt number and pressure drop in microchannels both with and without an MFI installed. The MFI increased the average Nusselt number by 2.9x due to increased fluid mixing. The pressure drop through the MFI was found to be on average five times higher than the empty channel due to reduced flow cross-section area. The network pressure drop model yielded a percent error at low Reynolds numbers of 5.2%. Subsequently, a 3.5 kW HTμR made of Inconel 625 was designed for waste heat recovery with an inlet temperature of 850°C. A subscale HTμR was fabricated and tested to validate the 3.5 kW design. The sub-scale five layer HTμR was tested with a hot side inlet temperature of 300°C. The sub-scale device performed as expected in terms of effectiveness (4.3% error), duty (4.3% error), and MFI channel pressure drop (-2.6% error). These results were used to scale a 3.5 kW Inconel 625 HTμR with a heat transfer surface area density of 1,633 m²/m³, a volumetric heat transfer coefficient of 2.3 MW/(m³K), and a volumetric heat transfer rate of 32 MW/m³ providing improved results versus high temperature recuperator designs in literature. Close

• 2. [Article] Integrated dual cycle energy recovery using thermoelectric conversion and an organic Rankine bottoming cycle

  Hot engine exhaust and industrial process exhaust represents a resource that is often rejected to the environment without further utilization. This resource is prevalent in the transportation and industrial ...

  Citation × Citation Citation Abstract Copy Title: Integrated dual cycle energy recovery using thermoelectric conversion and an organic Rankine bottoming cycle Author: Miller, Erik W. Hot engine exhaust and industrial process exhaust represents a resource that is often rejected to the environment without further utilization. This resource is prevalent in the transportation and industrial process sectors, but stationary engine-generator systems also typically do not utilize this resource. Engine exhaust is considered high grade heat and can potentially be utilized by various approaches to produce electricity or to drive heating and cooling systems. This thesis describes a model system that employs thermoelectric conversion as a topping cycle integrated with an organic Rankine bottoming cycle for waste heat utilization. This approach is being developed to fully utilize the thermal energy contained in hot exhaust streams. This thesis investigates several system configurations each composed of a high temperature heat exchanger which extracts thermal energy for driving the thermoelectric conversion elements and a closely integrated bottoming cycle to capture the large amount of remaining thermal energy in the exhaust stream. The models differ by how they arrange specific heat exchangers in the system. Many interacting parameters that define combined system operation are employed in the models to determine overall system performance including output power, efficiency, and total energy utilization factors. In addition, the model identifies a maximum power operating point for the combined system. That is, the model can identify the optimal amount of heat to remove from the exhaust flow to drive the thermoelectric elements for maximizing the combined cycle output. The model has been developed such that the impact of heat exchanger UA[subscript h] values, thermal resistances, and the thermoelectric figure-of-merit (ZT) can be investigated in the context of system operation. The model also has the ability to simultaneously determine the effect of each cycle design parameter on the performance of the overall system, thus giving the ability to utilize as much waste heat as possible. Key analysis results are presented showing the impact of critical design parameters on power output, system performance and inter-relationships between design parameters in governing performance. Title: Integrated dual cycle energy recovery using thermoelectric conversion and an organic Rankine bottoming cycle Author: Miller, Erik W. Hot engine exhaust and industrial process exhaust represents a resource that is often rejected to the environment without further utilization. This resource is prevalent in the transportation and industrial process sectors, but stationary engine-generator systems also typically do not utilize this resource. Engine exhaust is considered high grade heat and can potentially be utilized by various approaches to produce electricity or to drive heating and cooling systems. This thesis describes a model system that employs thermoelectric conversion as a topping cycle integrated with an organic Rankine bottoming cycle for waste heat utilization. This approach is being developed to fully utilize the thermal energy contained in hot exhaust streams. This thesis investigates several system configurations each composed of a high temperature heat exchanger which extracts thermal energy for driving the thermoelectric conversion elements and a closely integrated bottoming cycle to capture the large amount of remaining thermal energy in the exhaust stream. The models differ by how they arrange specific heat exchangers in the system. Many interacting parameters that define combined system operation are employed in the models to determine overall system performance including output power, efficiency, and total energy utilization factors. In addition, the model identifies a maximum power operating point for the combined system. That is, the model can identify the optimal amount of heat to remove from the exhaust flow to drive the thermoelectric elements for maximizing the combined cycle output. The model has been developed such that the impact of heat exchanger UA[subscript h] values, thermal resistances, and the thermoelectric figure-of-merit (ZT) can be investigated in the context of system operation. The model also has the ability to simultaneously determine the effect of each cycle design parameter on the performance of the overall system, thus giving the ability to utilize as much waste heat as possible. Key analysis results are presented showing the impact of critical design parameters on power output, system performance and inter-relationships between design parameters in governing performance. Close