Recuperative heat exchanger system
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Solution Overview
Problem
Conventional recuperative heat exchanger systems for Supercritical CO2 Brayton thermal power cycles face challenges in high-pressure, high-temperature operation, leading to mechanical design constraints, increased costs, and reduced efficiency due to the need for multiple heat exchange units and extensive pipework.
Innovation Solution
A recuperative heat exchanger system with a precool section, minor section, and major section, utilizing a combination of Printed Circuit Heat Exchangers (PCHE) and Shell and Tube Heat Exchangers, which splits the exhaust gas flow through curved flow loops and heat recovery sections to efficiently manage high-pressure and high-temperature conditions, reducing mechanical stress and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual heat exchange units are used to achieve high-pressure high-temperature heat exchange, then heat exchange effectiveness is improved, but device complexity and capital cost increase
Solution Approach 1:
The patent combines multiple heat exchange functions into a single integrated heat exchanger unit. The device performs both high-pressure heat exchange and low-pressure heat exchange simultaneously within one compact structure, eliminating the need for multiple separate heat exchange units and extensive piping networks. This merging approach maintains heat exchange effectiveness while dramatically reducing system complexity and capital cost.
Solution Approach 2:
The heat exchanger is designed with multi-functionality to handle different pressure levels and temperature ranges within a single device. It can simultaneously perform heat exchange operations for both high-pressure and low-pressure streams, making it a universal heat exchange solution that replaces multiple specialized units.
2Productivity
If turbine operates at higher temperatures above 600°C to increase efficiency, then power generation efficiency is improved, but mechanical design constraints and material requirements worsen
Solution Approach 1:
The patent employs parameter changes by utilizing phase transition of water (from liquid to steam) to transfer thermal energy. The heat exchanger converts thermal energy from high-temperature exhaust gases into thermal energy of steam at appropriate pressure and temperature levels for turbine operation. This parameter transformation allows efficient energy utilization while protecting downstream components from excessive temperatures.
Solution Approach 2:
The heat exchanger acts as an intermediary device between the high-temperature exhaust gas stream and the working fluid (water/steam). It mediates the thermal energy transfer, converting the high-temperature thermal energy into a form suitable for turbine operation without exposing the turbine and associated mechanical components to the extreme temperatures, thus resolving the mechanical design constraints.
3Productivity
If high-pressure high-temperature heat exchange is implemented, then power generation efficiency is improved, but capital cost increases due to extensive equipment and pipe work
Solution Approach 1:
The patent merges multiple heat exchange functions and pressure level handling into a single integrated device, eliminating the need for multiple separate heat exchangers and extensive piping. This consolidation dramatically reduces equipment quantity, installation complexity, and capital cost while maintaining the ability to perform high-pressure heat exchange for efficient power generation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system minimizes life cycle costs, increases reliability, and improves thermal energy exchange efficiency by precooling exhaust gases to below 575°C, reducing mechanical design constraints and allowing for lighter, more compact designs with reduced material usage and assembly time.
Implementation Method 1
heat exchangers to receive and cool exhaust gases
Implementation Method 2
flowing the exhaust gases through a first minor heat exchanger and to a second minor heat exchanger via one or more curved flow loops
Implementation Method 3
flowing the exhaust gases, in the minor section, through a first minor heat exchanger of the minor section and to a second minor heat exchanger of the minor section via one or more curved flow loops
Data Source
AI summary
A system may include a turbine and a recuperative heat exchanger system. The recuperative heat exchanger system is configured to receive exhaust gases from the turbine. The recuperative heat exchanger system may include a precool section to cool the exhaust gases, a major heating section to receive the cooled the exhaust gases, and a minor heating section to receive the cooled the exhaust gases.