A novel type of additively manufactured high pressure mini-channel heat exchanger for precooling in hydrogen refueling stations

verfasst von: R. Kahlfeld, F. Müller, H. Müntefering, P. Gembarski, R. Steinhoff, S. Kabelac
Abstract: During refueling supercritical hydrogen into high pressure storage tanks, the fluid has to be cooled down to temperatures between -33°C and -40°C before entering the vehicle fuel tank. This cooling takes place while the hydrogen is at a pressure of up to 87.5 MPa. The requirements for the heat exchanger performing this task are very high. It has to be pressure resistant, compact enough to fit in the dispenser column and provide a high thermal performance to ensure a fast refueling with high mass flow rates. Only few conventional manufactured heat exchangers are able to fulfil these requirements. With the rise of additive manufacturing technology, especially laser powder bed fusion, new heat exchangers produced without use of conventional joining technologies can be realized. This manuscript presents a new type additively manufactured of mini-channel heat exchanger. It is developed in a joint research project involving the Leibniz University Hanover and an industrial heat exchanger manufacturer. The apparatus has a design pressure of 105 MPa and will be suited to be used in hydrogen refueling stations. The thermal requirements and the design of the apparatus are described. Thermal power and pressure drop for the full-size heat exchanger are calculated via a cell model. Scaled smaller heat exchangers made of 1.4404 stainless steel are additively manufactured via laser powder bed fusion (LPBF). The thermofluiddynamical performance of the scaled apparatus is measured in a testbench to verify the applicability of the used correlations. Deviations in hydraulic diameter and surface roughness are taken into account. Existing correlations are fitted to the new geometry.
Organisationseinheit(en): Institut für Thermodynamik
Institut für Produktentwicklung und Gerätebau
Externe Organisation(en): Funke Wärmeaustauscher Apparatebau GmbH
Typ: Konferenzaufsatz in Fachzeitschrift
Journal: Journal of Physics: Conference Series
Band: 2766
Anzahl der Seiten: 7
ISSN: 1742-6588
Publikationsdatum: 2024
Publikationsstatus: Veröffentlicht
Peer-reviewed: Ja
ASJC Scopus Sachgebiete: Allgemeine Physik und Astronomie
Elektronische Version(en): https://doi.org/10.1088/1742-6596/2766/1/012187 (Zugang: Offen)

BibTeX

@article{69101ab214db4163849acaaf6164dc11,
title = "A novel type of additively manufactured high pressure mini-channel heat exchanger for precooling in hydrogen refueling stations",
abstract = "During refueling supercritical hydrogen into high pressure storage tanks, the fluid has to be cooled down to temperatures between -33°C and -40°C before entering the vehicle fuel tank. This cooling takes place while the hydrogen is at a pressure of up to 87.5 MPa. The requirements for the heat exchanger performing this task are very high. It has to be pressure resistant, compact enough to fit in the dispenser column and provide a high thermal performance to ensure a fast refueling with high mass flow rates. Only few conventional manufactured heat exchangers are able to fulfil these requirements. With the rise of additive manufacturing technology, especially laser powder bed fusion, new heat exchangers produced without use of conventional joining technologies can be realized. This manuscript presents a new type additively manufactured of mini-channel heat exchanger. It is developed in a joint research project involving the Leibniz University Hanover and an industrial heat exchanger manufacturer. The apparatus has a design pressure of 105 MPa and will be suited to be used in hydrogen refueling stations. The thermal requirements and the design of the apparatus are described. Thermal power and pressure drop for the full-size heat exchanger are calculated via a cell model. Scaled smaller heat exchangers made of 1.4404 stainless steel are additively manufactured via laser powder bed fusion (LPBF). The thermofluiddynamical performance of the scaled apparatus is measured in a testbench to verify the applicability of the used correlations. Deviations in hydraulic diameter and surface roughness are taken into account. Existing correlations are fitted to the new geometry.",
author = "R. Kahlfeld and F. M{\"u}ller and H. M{\"u}ntefering and P. Gembarski and R. Steinhoff and S. Kabelac",
note = "Publisher Copyright: {\textcopyright} Published under licence by IOP Publishing Ltd.; 9th European Thermal Sciences Conference, EUROTHERM 2024 ; Conference date: 10-06-2024 Through 13-06-2024",
year = "2024",
doi = "10.1088/1742-6596/2766/1/012187",
language = "English",
volume = "2766",
journal = "Journal of Physics: Conference Series",
issn = "1742-6588",
publisher = "IOP Publishing Ltd.",
}