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The UHTHE/EFCC/J1 Project: design, realization and testing of an ultra high temperature heat exchanger module for industrial applications

Objective



Objectives

The objective is to develop an Ultra High Temperature Heat Exchanger (UHTHE) based on a modular design to be applied in the consumption peak of around 1450°C, typical for some industrial applications. New construction materials are candidates and in particular ceramic matrix composites (CMCs), for reasons of process efficiency and reliability in operation. The component will modernize industrial installations and produce innovative high temperature technologies in industries, due to the great benefits of recovering heat wasted at high temperatures. The potential use of the component in energy and process industry-related applications will be investigated.

Technical Approach

Starting from the process requirements identified for both process industry-related and energy-related applications, a complete study of a shell and bayonet-tubes exchanger is carried out.

The project encompasses three technical areas :
- Application & Requirements : analysis of various industry and energy related applications and definition of the UHTHE process and functional requirements.
- Design. The UHTHE module is designed by means of both computer codes developed ad hoc, and 3-D CFD (Computational Fluid Dynamics) and FE (Finite Element) structural commercial codes.
- Characterization & Testing. The characterization phase is mainly devoted to bench scale tests regarding fouling/corrosion, heat intensificatioin devices and joinings; in details the tests concern :
. scaling/fouling in a coal combustion environment (in a large scale 0.5 MW furnace);
. process intensification devices (in bench scale tests, with cold and hot fluids);
. reliability of the tube-to-tubesheet joints (in hot pressurised tests)
Expected Achievements and Exploitation

The main outputs of the project are :
- A conceptual design of the shell and tube UHTHE, in terms of modularity choice, (sub)components description, assembly drawing;
- A simplified computer code integrating thermofluidynamic, heat transfer, mechanical and thermomechanical aspects;
- The results from fouling/corrosion tests carried out on a ceramic tube bundle under flue gases derived from the combustion of two different European coals;
- The results of testing carried out on Process Intensification Devices and on tube-to-tubesheet joints;
- A set of drawings for construction of both the metallic and refractory parts of the UHTHE.

The module will also be used to develop the Externally Fired Cycle (EFCC), which is a promising clean coal technology in the mid to long term power generation.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

ANSALDO RICERCHE SPA*
Address
Corso Perrone 25
16152 Genova
Italy

Participants (13)

Babcock & Wilcox Española S.A.
Spain
Address
27,Alameda De Recalde 27
48080 Bilbao
Balcke-Dürr GmbH
Germany
Address
2,Hombergerstrasse 2
40882 Ratingen
CINAR LTD.
United Kingdom
Address
11,Elvaston Place 11
SW7 5QG London
CINAR SA
Greece
Address
4,H. Mexi Street 4
11528 Athens
Centro Sviluppo Materiali SpA
Italy
Address
24 A,corso Perrone Romano
16152 Genova
Commissariat à l'Energie Atomique (CEA)
France
Address
Centre D'études De Grenoble
38041 Grenoble
Ente Nazionale per l'Energia Elettrica SpA (ENEL)
Italy
Address
Via Andrea Pisano 120
56100 Pisa
Ente per le Nuove Tecnologie l'Energia e l'Ambiente (ENEA)
Italy
Address
Via Anguillarese 301
00060 Santa Maria Di Galeria Roma
Mitsui Babcock Energy Ltd (MBEL)
United Kingdom
Address
11 The Boulevard
RH10 1UX Crawley
Rheinisch-Westfälische Technische Hochschule Aachen
Germany
Address
32,Nizzaallee 32
52072 Aachen
Schunk Ingenieurkeramik GmbH
Germany
Address
5,Hanns-martin-schleier-strasse
47877 Willich
UNIVERSITY OF WALES CARDIFF
United Kingdom
Address
Newport Road, Queen's Buildings, The Parade
CF2 3TB Cardiff
Vereinigte Energiewerke AG
Germany
Address

12681 Berlin