Heat exchanger designers need reliable thermal-hydraulic correlations to optimize heat exchanger designs. This work combines an adaptive sampling method with a Computational Fluid Dynamics (CFD) simulator to obtain increased accuracy and validity range of heat transfer and pressure drop predictions using a limited number of data points. Correlation efficacy was evaluated based on a steam generator case study. The sensitivity to the design parameters was analyzed in detail. The RMSE (root mean square error) of the developed correlations were reduced, through CFD sampling, from 28% to 15% for pressure drop, and from 33% to 25% heat transfer, compared to regression on experimental data only. The best reference correlations have RMSE values of 43% and 33% on pressure drop and heat transfer, respectively, on an independent validation set. Indeed, a radically different fin-tube geometry was suggested for the case study, compared to results using the Escoa correlations.The developed correlations show good to excellent agreement with trends in the CFD model. The quantitative error of predicted heat transfer and pressure drop coefficients at the case study optimum, however, was as large as those of the Escoa correlations. More data are likely needed to improve accuracy for compact heat exchanger designs further.

The fabrication and performance of wicks for flat heat pipe applications produced by sintering a filamentary nickel powder has been investigated. Tape casting was used as an intermediate step in the wick production process. Thermogravimetric analysis was used to study the burn-off of the organic binder used and to study the oxidation and reduction processes of the nickel. The wicks produced were flat, rectangular and intended for liquid transport in the upwards vertical direction. Rate-of-rise experiments using heptane were used to test the flow characteristics of the wicks. The wick porosities were measured using isopropanol. The heat transfer limitation constituted by the vapour static pressure and the capillary pressure was discussed. The influence on wick performance by using pore former in the manufacturing was studied. When P_cap/P_sat > 1, the use of a pore former to increase the wick permeability will always improve the wick performance. When P_cap/P_sat < 1, it was shown that if the effective pore radius and the permeability increase with an equal percentage the overall influence on the wick capacity is negative. A criterion for a successful pore former introduction is proposed and the concept of a pore former evaluation plot is presented.

Silica precipitation from high-enthalpy, depressurized supercritical fluids is investigated to determine the best method for accessing the scaling potential as a function of time, position and fluid composition. The most relevant knowledge application is for geothermal sources where the wells are drilled closed to magma and the temperature gradients in the rock are very high. The power potential per well for such a system is large compared to conventional geothermal power production, but several knowledge gaps, among them mineral precipitation from produced fluids, limit commercial use. For the high-enthalpy supercritical well fluid used as a base case in this review, conventional methods for reducing the silica content before it enters a turbine limit the power output. Knowledge of the particle-number density, size and time scales of growth in different depressurization scenarios, along with the silica solubility, kinetics and morphology, is essential to handle deposits and avoid scaling in inconvenient parts of the power plant. Experimental data on the precipitation of silica from highly supersaturated superheated steam are scarce, and it is known that the kinetics of precipitation in steam differ from those of liquid water. We argue that to quantify the number of solids in the depressurized supercritical fluid and superheated steam, dividing the process into three separate but dependable mathematical steps is a reliable approach: (1) the nucleation of nanocolloids, (2) growth by agglomeration, and (3) deposition onto a surface.

Heat at high temperatures, in this work 400–650 °C, can be recovered by use of cooling panels/heat pipes in the walls of aluminum electrolysis cells. For this application a flat vertical heat pipe for heat transfer from a unilateral heat source was analyzed theoretically and in the laboratory, with special emphasis on the performance of the wick. In this heat pipe a wick of compressed nickel foam covered only the evaporator surface, and potassium was used as the working fluid. The magnitudes of key thermal resistances were estimated analytically and compared. Operating temperatures and wick performance limits obtained experimentally were compared to predictions. Thermal deformation due to unilateral heat flux was analyzed by the use of COMSOL Multiphysics^®. The consequences of hot spots at different locations on the wick were analyzed by use of a numerical 2D model. A vertical rectangular wick was shown to be most vulnerable to hot spots at the upper corners.

This article presents the results of an experimental investigation of silica deposition from depressurized supercritical steam. The case investigated is relevant for supercritical geothermal reservoirs with high temperature and pressure, where silica content is significant and deposition occurs rapidly upon depressurization. The purpose of the presented experiments is to accurately measure the deposited mass in two different areas in a flow tube and mathematically relate the measurement to particle formation behavior. In addition, SEM analysis permits valuable insight into the morphology of the scale formed under these conditions. The measured deposition is caused by silica solids formed when depressurizing supercritical fluids from around 350 bar and 500 °C by an isenthalpic valve to a state of superheated steam and pressures ranging from 60 to 150 bar. A test rig was designed, fabricated, and used for this purpose. The deposition mechanisms differ from silica particle formation in the water phase and the limited experimental research for the investigated conditions makes the gathered data highly interesting. The measured results are compared to validated models for deposition in straight pipes. The knowledge obtained on silica solidification and deposition can be used to optimize steam treatment of high-temperature pressurized geothermal sources for maximum power utilization by aiding in the development of advanced prediction tools for scaling and mineral extraction.