Rational design process for gas turbine exhaust to supercritical CO2 waste heat recovery heat exchanger using topology optimization
Rational design process for gas turbine exhaust to supercritical CO2 waste heat recovery heat exchanger using topology optimization
复制标题
采用拓扑优化的燃气轮机排气至超临界CO2余热回收换热器的合理设计过程
DOI：
10.1016/j.applthermaleng.2023.121670
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发表时间：
2024
影响因子：
6.4
通讯作者：
Rattner, Alexander S.
中科院分区：
文献类型：
--
作者：
Adil, Nosherwan;Dryepondt, Sebastian N.;Kulkarni, Anand;Geoghegan, Patrick J.;Zhang, Xiang;Alkandari, Abdulaziz;Rattner, Alexander S.
添加剂制造(AM)技术和拓扑优化方法的进步使热交换器性能的复杂新颖设计成为可能。这些工具已被证明可用于开发考虑局部或部件级性能因素(例如，单位体积的热传递)的高性能散热器。为了在更大规模的能源系统中利用这种能力，需要考虑系统级因素的结构化设计方法，例如生产成本、循环级效率和操作限制。这项研究旨在开发和评估一种合理的方法来设计适用于此类应用的热经济最佳换热器。通过开发用于超临界二氧化碳(SCO2)动力循环的一次热交换器(PHX)来说明这种方法，回收6兆瓦规模的天然气透平的废热。建议的方法从详细的热力学循环模型开始，然后将其扩展到考虑技术经济学。接下来，识别最佳PHX换热容量目标，并基于操作特性选择高级几何形状。然后将该几何形状划分为重复的2D棱柱单元，并对其应用拓扑优化以识别高性能的热传递几何形状。这一过程的一个关键方面是使用总PHX质量作为目标函数来优化单元几何形状，该目标函数代表了生产成本的替代。与优化局部换热和流动阻力系数的方法相比，这导致了不同的设计。使用具有代表性的局部热流体性能目标函数开发了第二个拓扑优化设计，发现对于相同的单元尺寸，所需质量是系统级技术经济目标所产生的设计质量的1.6倍。为了进行比较，开发了带有简单纵向翅片管的常规型PHX设计，发现它们需要的总质量比用所提出的工艺获得的设计质量大1.5×2或更多。将这种方法与详细的附加制造成本模型和经过实验验证的制造约束相结合，可以为未来能源系统的HX设计提供简化的工作流程。
Advances in additive manufacturing (AM) technologies and topology optimization methodologies are enabling sophisticated novel designs for heat exchanger performance. These tools have been demonstrated for development of high-performance heat sinks considering local or component-level performance factors (e.g., heat transfer per volume). To leverage such capabilities in larger-scale energy systems, structured design methodologies are needed that consider system-level factors, such as production cost, cycle-level efficiency, and operational constraints. This study seeks to develop and assess a rational approach for designing thermo-economically optimal heat exchangers for such applications. The methodology is illustrated through development of the Primary Heat Exchanger (PHX) for a supercritical carbon dioxide (sCO2) power cycle recovering exhaust heat from a 6 MW-scale natural gas turbine. The proposed approach begins with a detailed thermodynamic cycle model, which is then extended to account for techno-economics. Next, an optimal PHX heat transfer capacity target is identified, and a high-level geometry is selected based on operating characteristics. This geometry is then divided into repeating 2D prismatic unit cells, for which topology optimization is applied to identify high-performance heat transfer geometries. A key aspect of this process is that the unit cell geometries are optimized using the total PHX mass as the objective function, which represents a surrogate for production cost. This leads to distinct designs compared with approaches that optimize local heat transfer and flow resistance factors. A second topology-optimized design is developed using a representative local thermal-fluid performance objective function and is found to require 1.6× the mass of the design generated with the system-level techno-economic objective for the same unit cell size. Conventional-type PHX designs with simple longitudinally finned tubes are developed for comparison, and are found to require total masses 1.5× or greater than the design obtained with the proposed process. Integrating this approach with detailed additive manufacturing costing models and experimentally validated fabrication constraints can yield a streamlined workflow for HX design for future energy systems.
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DOI：
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DOI：
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发表时间：
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