Thermal-hydraulic performance of a high-temperature zigzag-channel printed circuit heat exchanger

Advanced nuclear reactors, such as hightemperature gas-cooled reactors (HTGRs) from the Generation IV nuclear systems, are designed with the capability of delivering high-pressure, hightemperature helium to power conversion units for electricity generation and industrial plants for process heat applications. The efficiency of the electricity generation and process heat applications of HTGRs is critically dependent upon an intermediate heat exchanger (IHX), which is a key component in transferring thermal energy from the primary coolant to a secondary coolant. Printed circuit heat exchangers (PCHEs) are promising to be employed in HTGR designs due to their capability for hightemperature, high-pressure applications and compactness. In the current study, a laboratory-scale zigzag-channel PCHE was fabricated and its heat transfer and pressure drop characteristics were investigated experimentally in a high-temperature helium test facility (HTHF). A commercial computational fluid dynamics (CFD) code, STAR-CCM+, was used to simulate the thermal-hydraulic performance of the fabricated PCHE with a simplified geometry model. Comparisons showed some differences between experimental data available for the zigzag-channel PCHE and the numerical results. Local thermal-hydraulic performance analyses indicated that fully-developed flow conditions and periodic changes were not observed, which could be attributed to the temperature variations along the flow channels, resulting in large fluid property variations. In addition, the effects of sharp-edged or rounded zigzag channel geometry were numerically evaluated. The use of rounded corners at each bend of the channels is recommended since this method can reduce the pressure drop on both the hot and cold sides of the heat exchanger while maintaining similar heat transfer capabilities.