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Optimal design of microtube recuperators for an indirect supercritical carbon dioxide recompression closed Brayton cycle

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  • Jiang, Yuan
  • Liese, Eric
  • Zitney, Stephen E.
  • Bhattacharyya, Debangsu

Abstract

This paper presents a baseline design and optimization approach developed in Aspen Custom Modeler (ACM) for microtube shell-and-tube exchangers (MSTEs) used for high- and low-temperature recuperation in a 10 MWe indirect supercritical carbon dioxide (sCO2) recompression closed Brayton cycle (RCBC). The MSTE-type recuperators are designed using one-dimensional models with thermal-hydraulic correlations appropriate for sCO2 and properties models that capture considerable nonlinear changes in CO2 properties near the critical and pseudo-critical points. Using the successive quadratic programming (SQP) algorithm in ACM, optimal recuperator designs are obtained for either custom or industry-standard microtubes considering constraints based on current advanced manufacturing techniques. The three decision variables are the number of tubes, tube pitch-to-diameter ratio, and tube diameter. Five different objective functions based on different key design measures are considered: minimization of total heat transfer area, heat exchanger volume, metal weight, thermal residence time, and maximization of compactness. Sensitivities studies indicate the constraint on the maximum number of tubes per shell does affect the number of parallel heat exchanger trains but not the tube selection, total number of tubes, tube length and other key design measures in the final optimal design when considering industry-standard tubes. In this study, the optimally designed high- and low-temperature recuperators have 47,000 3/32 in. tubes and 63,000 1/16 in. tubes, respectively. In addition, sensitivities to the design temperature approach and maximum allowable pressure drop are studied, since these specifications significantly impact the optimal design of the recuperators as well as the thermal efficiency and the economic performance of the entire sCO2 Brayton cycle.

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  • Jiang, Yuan & Liese, Eric & Zitney, Stephen E. & Bhattacharyya, Debangsu, 2018. "Optimal design of microtube recuperators for an indirect supercritical carbon dioxide recompression closed Brayton cycle," Applied Energy, Elsevier, vol. 216(C), pages 634-648.
    • Handle: RePEc:eee:appene:v:216:y:2018:i:c:p:634-648
    DOI: 10.1016/j.apenergy.2018.02.082
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    2. Robey, Ed & Ramesh, Sridharan & Sabau, Adrian S. & Abdoli, Abas & Black, James & Straub, Doug & Yip, Joe, 2022. "Design optimization of an additively manufactured prototype recuperator for supercritical CO2 power cycles," Energy, Elsevier, vol. 251(C).
    3. Cheng, Kunlin & Qin, Jiang & Sun, Hongchuang & Li, Heng & He, Shuai & Zhang, Silong & Bao, Wen, 2019. "Power optimization and comparison between simple recuperated and recompressing supercritical carbon dioxide Closed-Brayton-Cycle with finite cold source on hypersonic vehicles," Energy, Elsevier, vol. 181(C), pages 1189-1201.
    4. Renchuan Zheng & Erlei Gong & Jianzhong Li & Qian Yao & Zhaolong Nie, 2024. "Performance Analysis of Wave Rotor Combustor Integration into Baseline Engines: A Comparative Study of Pressure-Gain and Work Cycles," Energies, MDPI, vol. 17(9), pages 1-18, April.
    5. Edwin Espinel Blanco & Guillermo Valencia Ochoa & Jorge Duarte Forero, 2020. "Thermodynamic, Exergy and Environmental Impact Assessment of S-CO 2 Brayton Cycle Coupled with ORC as Bottoming Cycle," Energies, MDPI, vol. 13(9), pages 1-24, May.
    6. Zhou, Aozheng & Li, Xue-song & Ren, Xiao-dong & Song, Jian & Gu, Chun-wei, 2020. "Thermodynamic and economic analysis of a supercritical carbon dioxide (S–CO2) recompression cycle with the radial-inflow turbine efficiency prediction," Energy, Elsevier, vol. 191(C).
    7. Fan, Y.H. & Tang, G.H. & Sheng, Q. & Li, X.L. & Yang, D.L., 2023. "S–CO2 cooling heat transfer mechanism based on pseudo-condensation and turbulent field analysis," Energy, Elsevier, vol. 262(PA).
    8. Du, Yadong & Hu, Chenxing & Yang, Ce & Wang, Haimei & Dong, Wuqiang, 2022. "Size optimization of heat exchanger and thermoeconomic assessment for supercritical CO2 recompression Brayton cycle applied in marine," Energy, Elsevier, vol. 239(PD).
    9. Zhou, Aozheng & Li, Xue-song & Ren, Xiao-dong & Gu, Chun-wei, 2020. "Improvement design and analysis of a supercritical CO2/transcritical CO2 combined cycle for offshore gas turbine waste heat recovery," Energy, Elsevier, vol. 210(C).
    10. Liu, Guangxu & Huang, Yanping & Wang, Junfeng & Liu, Ruilong, 2020. "A review on the thermal-hydraulic performance and optimization of printed circuit heat exchangers for supercritical CO2 in advanced nuclear power systems," Renewable and Sustainable Energy Reviews, Elsevier, vol. 133(C).
    11. Dora Villada-Castillo & Guillermo Valencia-Ochoa & Jorge Duarte-Forero, 2023. "Thermohydraulic and Economic Evaluation of a New Design for Printed Circuit Heat Exchangers in Supercritical CO 2 Brayton Cycle," Energies, MDPI, vol. 16(5), pages 1-24, February.
    12. Jiang, Yuan & Liese, Eric & Zitney, Stephen E. & Bhattacharyya, Debangsu, 2018. "Design and dynamic modeling of printed circuit heat exchangers for supercritical carbon dioxide Brayton power cycles," Applied Energy, Elsevier, vol. 231(C), pages 1019-1032.

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