Advanced Heat Exchangers for Dry Cooling Systems, Phase II
- Ultramet, Pacoima, CA (United States)
Dry cooling systems are an option for industrial and utility power plants that cannot obtain permits for cooling water or where cooling water is unavailable. Currently available dry cooling systems are more expensive and less efficient than wet cooling systems, so significant improvements in efficiency are needed to make them economically viable. Previous attempts at using foams as cooling fin materials for power generating systems have focused on high thermal conductivity graphite foams made via the Oak Ridge process. Because these materials have high flow restrictions and hence low permeability with respect to air flow, their internal volume and surface area were not effectively used. Consequently, they performed poorly and offered no advantage over aluminum fins. A foam with a more open structure would provide increased permeability, enable greater airflow through the bulk material, increase the rate of heat transfer, and enable the material to outperform traditional fin structures. In this project, Ultramet designed, fabricated, and tested low flow restriction, high-efficiency foam-based heat exchangers. Calculations based on existing thermal and hydraulic data for Ultramet’s high-performance open-cell foams indicated that 65-ppi (pores per linear inch) pyrolytic graphite foam with a relative density of 15 vol%, produced by chemical vapor infiltration (CVI), would have an effectiveness significantly greater than that of a state-of-the-art Hamon/Balcke-Durr aluminum fin system and greater than that of the POCO graphite foams previously tested for the DOE National Energy Technology Laboratory. Using the same chevron design, test setup, and run conditions as were used with the Hamon/Balcke-Durr fin system and the POCO foams, Ultramet tested graphite foams with air flow velocities of 0.07–3.2 m/sec and pressure drops of 0.03–9.7 inH2O. The best-performing graphite foam architectures had air velocities in excess of 2.5 m/sec when the pressure drop was 1 inH2O. Because a foam-based system is more efficient than a fin-based system, a smaller heat exchanger installation can be used, significantly reducing the installation cost. Furthermore, because the foam-based system is physically smaller with no increase in flow restriction, less electrical power is needed to run the fans to drive the air through the condenser. The result is a decrease in both the installation and operating costs, which in turn will decrease the overall life cycle cost of the system.
- Research Organization:
- Ultramet, Pacoima, CA (United States)
- Sponsoring Organization:
- USDOE Office of Science (SC), Basic Energy Sciences (BES)
- Contributing Organization:
- Advanced Thermal and Environmental Concepts (ATEC, College Park, MD)
- DOE Contract Number:
- SC0011300
- OSTI ID:
- 1423747
- Type / Phase:
- SBIR (Phase II)
- Report Number(s):
- DOE-ULTRAMET-0011300; ULTRA-TR-17-16198
- Country of Publication:
- United States
- Language:
- English
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