Thermofluiddynamic Pre-design of a Primary Surface Heat Exchanger Under the Influence of Heat Radiation Using 1D/3D Coupled Simulation Method

Abstract

Within the Framework of the "TurboFuelCell (TFC)" a highly integrated and compact energy conversion system based on Micro Gas Turbine Solid Oxide Fuel Cell (MGT-SOFC) hybrid process is being developed by the team at BTU-Cottbus Senftenberg. This work focuses on the extension of the pre-design process of a primary surface heat exchanger (PSHX), which is a key component for the coupling between MGT and SOFC, using an 1D/3D hybrid simulation method for the understanding of its behaviour under the influence of heat radiation. In a MGT-SOFC hybrid process the high temperature heat exchanger plays an important role in preheating the fresh air to a minimum operation temperature necessary for SOFC. Due to the special location of this PSHX in the TFC, it is constantly exposed to heat radiation from the SOFC module, which requires additional consideration of its influence for better model accuracy. A first design, which is later extended through an 1D Flow network model, based on ϵ-NTU method is presented. A complete 3D-CFD simulation with consideration of heat radiation is initially employed for the whole flow process to examine the first design. However, this approach proves to be highly computationally expensive due to the large dimensional difference between the plenum for cathode exhaust air and the fine channels in the PSHX. To reduce the computational effort, the flow and heat transfer in the PSHX is modelled by 1D elements. The flow in the plenum is simulated by 3D-CFD, which better accounts for convection and thermal radiation. A comparison between 3D-CFD and 1D/3D hybrid model is performed. A significant reduction of simulation time and computing resources can be achieved for well calibrated hybrid model without compromising on accuracy. In the talk, the effect of insulation layer thickness variations on the heat transfer on the plenum side due to heat radiation and their influence on the heat exchanger efficiency are discussed. Consequently, design improvements are realized based on the previous findings. Finally, the 1D/3D hybrid simulation method is evaluated and prepared for the general applications in thermal management of machines based on coupled MGT-SOFC process.