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Verwertbare Ergebnisse
In the EC, the global distribution of energy used for industrial purpose generally shows two consumption peaks: the first peak ranges from 150 C and 250 C, whereas the second one is around 1450 C; at this latter temperature metallic super alloys and heat-resistant cast alloys cannot be used: the implementation of a module of an Ultra High Temperature Heat Exchanger (UHTHE) based on a modular design foreseeing the use of bayonet tubes (to be applied in the consumption peak around 1450* C, typical of the global distribution of energy for industrial purposes) allows to modernize industrial installations and to innovate high temperature technologies in industries.
New construction materials were adopted for reasons of process efficiency and reliability in service: ceramics, both advanced monolithics, at a higher development stage, and ceramic matrix composite (CMCs) were foreseen, thus exhibiting enhanced resistance against corrosion, when compared to metals.
The use of the above mentioned new materials in an industrial component like a heat exchanger needs a complete understanding of thermofluidynamics and mechanical behaviour of such component. Then, a very strong design activity was carried out, covering all the physical phenomena occurring in the component, in order to determine temperature profiles, pressure drops, velocity fields, stresses distribution, and in order to foresee the scaling/fouling of the tubes.
The project designing an UHTHE (Ultra High Temperature Heat Exchanger) started from the UHTHE process requirements and its potential use derived from an analysis of energy-related and process industry-related applications; a complete study of the shell and bayonet-tubes heat exchanger was carried out from both the thermofluidynamic and mechanical point of view. A complete set of drawings for construction concerning the metallic, the refractory conventional and advanced ceramic parts was produced. Furthermore, a supporting to the design test campaign in identified critical areas has been carried out. The project encompassed 3 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 was designed by means of both computer codes developed ad hoc, and 3-D CFD (Computational Fluid Dynamic) and FE (Finite Element) structural commercial codes. In the final design phase, particular emphasis was given to the tube-to-tubesheet desmountable joints and to the intensification devices necessary to increase the heat exchange between the fluids
- Characterization & Testing: the characterization phase was mainly devoted to bench scale tests regarding: fouling/corrosion, heat enhancing devices and joinings.
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