An additively-manufactured molten salt-to-supercritical carbon di-oxide primary heat exchanger for solar thermal power generation – Design and techno-economic performance

Tano, Ines-Noelly; Rasouli, Erfan; Ziev, Tracey; Wu, Ziheng; Lamprinakos, Nicholas; Seo, Junwon; Schulze Balhorn, Lukas; Vaishnav, Parth; Rollett, Anthony; Narayanan, Vinod

doi:10.1016/j.solener.2022.01.056

Title: An additively-manufactured molten salt-to-supercritical carbon di-oxide primary heat exchanger for solar thermal power generation – Design and techno-economic performance

Journal Article · 10 February 2022 · Solar Energy

DOI: https://doi.org/10.1016/j.solener.2022.01.056 · OSTI ID:1977654

^[1];

^[2];

^[3];

^[3]; Seo, Junwon ^[3];

^[4]; Vaishnav, Parth ^[5];

^[3];

^[2]

Univ. of California, Davis, CA (United States); OSTI
Univ. of California, Davis, CA (United States)
Carnegie Mellon Univ., Pittsburgh, PA (United States)
Univ. of California, Davis, CA (United States); RWTH Aachen Univ. (Germany)
Univ. of Michigan, Ann Arbor, MI (United States)

The design and techno-economic performance of a compact additively manufactured (AM) molten salt (MS)-to-supercritical carbon di-oxide (sCO2) primary heat exchanger (PHE) for solar thermal application is described. The PHE design consists of sCO2 flow through an array of microscale pin fins while the MS flows through mm-scale rectangular channels. Constraints imposed by AM using laser powder bed fusion method are considered in the design. Structural and fluid flow simulations are performed to arrive at a viable design of the core and headers. A simplified one-dimensional steady state model for the PHE is developed including the impact of surface roughness from the AM process. A process-based cost model is used to determine the tradeoff between thermofluidic design and manufacturing cost. A parametric study is performed using the thermo-fluidic and cost models to determine the set of geometrical and flow variables that result in high power density and low cost, while restricting the pressure drop on the sCO2 side to less than 2% of line pressure. Flow rates of MS and sCO2 were varied over heat capacity rate ratios ranging from 0.2 to 1. Results indicate that it is possible to design a low-pressure drop AM PHE with an effectiveness of 90% and a power density in excess of 10 MW/m3 (including headers). Fabrication of representative nickel superalloy specimens are shown to demonstrate that low-porosity parts with the requisite dimensional tolerance of PHE core can be generated.

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: Univ. of California, Davis, CA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Renewable Power Office. Solar Energy Technologies Office

Grant/Contract Number:: EE0008536

OSTI ID:: 1977654

Journal Information:: Solar Energy, Journal Name: Solar Energy Journal Issue: C Vol. 234; ISSN 0038-092X

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (35)

Exploring the fabrication limits of thin-wall structures in a laser powder bed fusion process Wu, Ziheng; Narra, Sneha Prabha; Rollett, Anthony The International Journal of Advanced Manufacturing Technology, Vol. 110, Issue 1-2 https://doi.org/10.1007/s00170-020-05827-4	journal	August 2020
Heat Transfer from Tubes in Crossflow Žukauskas, A. Advances in Heat Transfer https://doi.org/10.1016/S0065-2717(08)70038-8	book	January 1972
A numerical evaluation of next generation additive layer manufactured inter-layer channel heat exchanger Greiciunas, Evaldas; Borman, Duncan; Summers, Jonathan Applied Thermal Engineering, Vol. 162 https://doi.org/10.1016/j.applthermaleng.2019.114304	journal	November 2019
Bioinspired heat exchangers based on triply periodic minimal surfaces for supercritical CO2 cycles Li, Weihong; Yu, Guopeng; Yu, Zhibin Applied Thermal Engineering, Vol. 179 https://doi.org/10.1016/j.applthermaleng.2020.115686	journal	October 2020
Additive manufacturing (3D printing): A review of materials, methods, applications and challenges Ngo, Tuan D.; Kashani, Alireza; Imbalzano, Gabriele Composites Part B: Engineering, Vol. 143 https://doi.org/10.1016/j.compositesb.2018.02.012	journal	June 2018
Thermal-hydraulic analysis of sinusoidal fin-based printed circuit heat exchangers for supercritical CO2 Brayton cycle Saeed, Muhammad; Kim, Man-Hoe Energy Conversion and Management, Vol. 193 https://doi.org/10.1016/j.enconman.2019.04.058	journal	August 2019
Forced convective heat transfer across a pin fin micro heat sink Peles, Yoav; Koşar, Ali; Mishra, Chandan International Journal of Heat and Mass Transfer, Vol. 48, Issue 17 https://doi.org/10.1016/j.ijheatmasstransfer.2005.03.017	journal	August 2005
Additive manufacturing of pyramidal pin fins: Height and fin density effects under forced convection Cormier, Yannick; Dupuis, Philippe; Farjam, Aslan International Journal of Heat and Mass Transfer, Vol. 75 https://doi.org/10.1016/j.ijheatmasstransfer.2014.03.053	journal	August 2014
Flow structure identification and analysis in fin arrays produced by cold spray additive manufacturing Dupuis, Philippe; Cormier, Yannick; Fenech, Marianne International Journal of Heat and Mass Transfer, Vol. 93 https://doi.org/10.1016/j.ijheatmasstransfer.2015.10.019	journal	February 2016
An investigation of a multi-layered oscillating heat pipe additively manufactured from Ti-6Al-4V powder Ibrahim, Omar T.; Monroe, J. Gabriel; Thompson, Scott M. International Journal of Heat and Mass Transfer, Vol. 108 https://doi.org/10.1016/j.ijheatmasstransfer.2016.12.063	journal	May 2017
Pressure loss and heat transfer performance for additively and conventionally manufactured pin fin arrays Kirsch, Kathryn L.; Thole, Karen A. International Journal of Heat and Mass Transfer, Vol. 108 https://doi.org/10.1016/j.ijheatmasstransfer.2017.01.095	journal	May 2017
Pitch and aspect ratio effects on single-phase heat transfer through microscale pin fin heat sinks Rasouli, Erfan; Naderi, Cameron; Narayanan, Vinod International Journal of Heat and Mass Transfer, Vol. 118 https://doi.org/10.1016/j.ijheatmasstransfer.2017.10.105	journal	March 2018
Numerical analysis of flow and conjugate heat transfer for supercritical CO2 and liquid sodium in square microchannels Khalesi, Javad; Sarunac, Nenad International Journal of Heat and Mass Transfer, Vol. 132 https://doi.org/10.1016/j.ijheatmasstransfer.2018.12.071	journal	April 2019
Experimental study on the heat transfer performance of a molten-salt printed circuit heat exchanger with airfoil fins for concentrating solar power Wang, Wen-Qi; Qiu, Yu; He, Ya-Ling International Journal of Heat and Mass Transfer, Vol. 135 https://doi.org/10.1016/j.ijheatmasstransfer.2019.02.012	journal	June 2019
Heat transfer and friction of molten salt and supercritical CO2 flowing in an airfoil channel of a printed circuit heat exchanger Shi, Hong-Yuan; Li, Ming-Jia; Wang, Wen-Qi International Journal of Heat and Mass Transfer, Vol. 150 https://doi.org/10.1016/j.ijheatmasstransfer.2019.119006	journal	April 2020
Thermal hydraulic performance of printed circuit heat exchanger with various channel configurations and arc ribs for SCO2 Brayton cycle Jing, Qi; Xie, Yonghui; Zhang, Di International Journal of Heat and Mass Transfer, Vol. 150 https://doi.org/10.1016/j.ijheatmasstransfer.2019.119272	journal	April 2020
Experimental investigation of pressure drop and heat transfer in high temperature supercritical CO2 and helium in a printed-circuit heat exchanger Katz, Alon; Aakre, Shaun R.; Anderson, Mark H. International Journal of Heat and Mass Transfer, Vol. 171 https://doi.org/10.1016/j.ijheatmasstransfer.2021.121089	journal	June 2021
Convective heat transfer performance of airfoil heat sinks fabricated by selective laser melting Ho, J. Y.; Wong, K. K.; Leong, K. C. International Journal of Thermal Sciences, Vol. 114 https://doi.org/10.1016/j.ijthermalsci.2016.12.016	journal	April 2017
Thermo-hydraulic analysis of compact heat exchanger for a simple recuperated sCO2 Brayton cycle Pandey, V.; Kumar, P.; Dutta, P. Renewable and Sustainable Energy Reviews, Vol. 134 https://doi.org/10.1016/j.rser.2020.110091	journal	December 2020
Survey and evaluation of equations for thermophysical properties of binary/ternary eutectic salts from NaCl, KCl, MgCl2, CaCl2, ZnCl2 for heat transfer and thermal storage fluids in CSP Li, Yuanyuan; Xu, Xiankun; Wang, Xiaoxin Solar Energy, Vol. 152 https://doi.org/10.1016/j.solener.2017.03.019	journal	August 2017
Studies on the thermal-hydraulic performance of zigzag channel with supercritical pressure CO2 Zhang, Haiyan; Guo, Jiangfeng; Huai, Xiulan The Journal of Supercritical Fluids, Vol. 148 https://doi.org/10.1016/j.supflu.2019.03.003	journal	June 2019
Heat Transfer Nellis, Gregory; Klein, Sanford Cambridge University Press https://doi.org/10.1017/CBO9780511841606	book	January 2008
Ceramic–metal composites for heat exchangers in concentrated solar power plants Caccia, M.; Tabandeh-Khorshid, M.; Itskos, G. Nature, Vol. 562, Issue 7727 https://doi.org/10.1038/s41586-018-0593-1	journal	October 2018
Characterization of surface roughness effects on pressure drop in single-phase flow in minichannels Kandlikar, Satish G.; Schmitt, Derek; Carrano, Andres L. Physics of Fluids, Vol. 17, Issue 10 https://doi.org/10.1063/1.1896985	journal	January 2005
Thermo-Hydraulic Performance of Printed Circuit Heat Exchanger With Different Cambered Airfoil Fins Chu, Wen-Xiao; Bennett, Katrine; Cheng, Jie Heat Transfer Engineering, Vol. 41, Issue 8 https://doi.org/10.1080/01457632.2018.1564203	journal	May 2019
Effect of Tip Clearance on the Thermal and Hydrodynamic Performance of a Shrouded Pin Fin Array Moores, Kevin A.; Joshi, Yogendra K. Journal of Heat Transfer, Vol. 125, Issue 6 https://doi.org/10.1115/1.1621897	journal	November 2003
Nusselt Number and Friction Factor of Staggered Arrays of Low Aspect Ratio Micropin-Fins Under Cross Flow for Water as Fluid Prasher, Ravi S.; Dirner, John; Chang, Je-Young Journal of Heat Transfer, Vol. 129, Issue 2 https://doi.org/10.1115/1.2402179	journal	April 2006
Build Direction Effects on Microchannel Tolerance and Surface Roughness Snyder, Jacob C.; Stimpson, Curtis K.; Thole, Karen A. Journal of Mechanical Design, Vol. 137, Issue 11 https://doi.org/10.1115/1.4031071	journal	October 2015
Roughness Effects on Flow and Heat Transfer for Additively Manufactured Channels Stimpson, Curtis K.; Snyder, Jacob C.; Thole, Karen A. Journal of Turbomachinery, Vol. 138, Issue 5 https://doi.org/10.1115/1.4032167	journal	January 2016
Heat Transfer and Pressure Loss Measurements in Additively Manufactured Wavy Microchannels Kirsch, Kathryn L.; Thole, Karen A. Journal of Turbomachinery, Vol. 139, Issue 1 https://doi.org/10.1115/1.4034342	journal	September 2016
Scaling Roughness Effects on Pressure Loss and Heat Transfer of Additively Manufactured Channels Stimpson, Curtis K.; Snyder, Jacob C.; Thole, Karen A. Journal of Turbomachinery, Vol. 139, Issue 2 https://doi.org/10.1115/1.4034555	journal	September 2016
Effects of Geometry, Spacing, and Number of Pin Fins in Additively Manufactured Microchannel Pin Fin Arrays Ferster, Katharine K.; Kirsch, Kathryn L.; Thole, Karen A. Journal of Turbomachinery, Vol. 140, Issue 1 https://doi.org/10.1115/1.4038179	journal	October 2017
Concentrating Solar Power Gen3 Demonstration Roadmap Mehos, Mark; Turchi, Craig; Vidal, Judith https://doi.org/10.2172/1338899	report	January 2017
Performance of Pin Fin Cast Aluminum Coldwalls, Part 1: Friction Factor Correlations Short, B. Elliott; Raad, Peter E.; Price, Donald C. Journal of Thermophysics and Heat Transfer, Vol. 16, Issue 3 https://doi.org/10.2514/2.6692	journal	July 2002
Performance of Pin Fin Cast Aluminum Coldwalls, Part 2: Colburn j-Factor Correlations Short, B. Elliott; Raad, Peter E.; Price, Donald C. Journal of Thermophysics and Heat Transfer, Vol. 16, Issue 3 https://doi.org/10.2514/2.6693	journal	July 2002

Similar Records

A Scalable Compact Additively Manufactured Molten Salt to Supercritical Carbon Dioxide Heat Exchanger for Solar Thermal Application

Journal Article · 2023 · Journal of Solar Energy Engineering · OSTI ID:2441277

Tano, Ines-Noelly; Rasouli, Erfan; Ziev, Tracey; +6 more

Additively Manufactured Molten Salt to Supercritical Carbon Dioxide Heat Exchanger

Technical Report · 2024 · OSTI ID:2448103

Narayanan, Vinod; Rasouli, Erfan; Rollett, Anthony D; +9 more

On-Sun Characterization of Microchannel Supercritical Carbon Dioxide Solar Thermal Receivers - Preliminary Findings

Conference · 2019 · OSTI ID:1571296

Rasouli, Erfan; Mande, Caton W.; Stevens, Matthew M.; +1 more

Related Subjects

14 SOLAR ENERGY
Energy & fuels
additive manufacturing
heat exchanger
molten salt
nickel superalloy
process-based cost model
supercritical carbon di-oxide

Title: An additively-manufactured molten salt-to-supercritical carbon di-oxide primary heat exchanger for solar thermal power generation – Design and techno-economic performance

Citation Formats

References (35)

Similar Records

Related Subjects