Study of Small Hydraulic Diameter Media for Improved Heat Exchanger Compactness

Solar radiation offers phenomenal potential for energy conversion with energy densities on the order of 1000W/m2 in locations with regularly clear skies. As always, the difficulty lies in finding a solar-electric conversion technology capable of producing electricity at a competitive cost. The SolarCAT (Solar Compressed Air Turbine) system produces electricity by releasing stored compressed air through a series of turbines with solar dish concentrators providing the required heat for efficient conversion to electricity. To minimize impact on capital cost, high recuperator effectiveness targets are sought but unlike typical fuel-fired micro-turbines, raising the recuperator effectiveness of the solar power system yields a benefit in overall system capital cost. Improving efficiency lowers the size and cost of the largest element of the system, namely the dish. In this study potential techniques for achieving a highly compact heat-transfer media were reviewed. Folded fin, packed beds, micro-tubes, lattice frame structures, metal foams, woven textile, and micro-machining techniques were assessed. Textile structures were selected as an appropriate medium to replace the internal folded fin of the SolarCAT recuperator. The relatively long flow (>150mm) path through the proposed screen wafers requires a model for fully-developed forced convective flow between parallel plates. A mathematical model was developed by integrating the results from the work of several authors in the field of textiles and porous media. #100 mesh sintered screen wafers were brazed between two 0.25mm stainless steel sheets and destructively tested to assess their tensile strength. Although iii optimization of the braze parameters was not completed, it was found that many samples survived exposure to internal pressures in excess of 50MPa. This study found that the use of sintered screen wafers to replace the internal folded fin of the SolarCAT recuperator would have advantages over the current design with respect to both overall recuperator effectiveness, size, and cost. Textile structures can be tailored to have wide range of fluid and heat-transfer properties depending on the application. The manufacturing process is relatively simple and could be cost-effective for high-volume production