advanced serpentine heat exchangers serpentine heat exchangers 2017building technologies office peer...
Post on 01-May-2018
217 Views
Preview:
TRANSCRIPT
Advanced Serpentine Heat Exchangers 2017 Building Technologies Office Peer Review
Daniel Bacellar bacellaroptimizedthermalsystemscom
Optimized Thermal Systems Inc
Project Summary
Timeline Start date 102016
Planned end date 102019
Key Milestones 1 Develop Optimized Fin Geometry 082017
2 Construct Prototype Heat Exchangers 032018
3 Commercialization Plan 102019
Budget Total Project $ to Date 2393797 bull DOE $1788440 bull Cost Share $605357
Total Project $ 663397 bull DOE $509563 bull Cost Share $153834
Key Partners Optimized Thermal Systems Inc
Heat Transfer Technologies (HTT)
United Technologies Research Center (UTRC)
Project Outcome Conceptualize serpentine heatexchangers for HVAC application aiming leakage reduction Design amp Optimize novel ldquodog-bonerdquo fin concepts that result in equivalent orbetter performance than current state-ofshythe-art tube-fin heat exchangers Prototype validate and commercialize
2
Purpose and Objectives
Problem Statement develop heat exchanger design and manufacturing solutions aiming to significantly reduce the direct and indirect impacts of refrigerant leakage in heating ventilating air conditioning and refrigeration (HVACampR) systems
Main Objectives bull Develop serpentine heat exchangers (SHX) with equivalent or better performance than
current state‐of‐the‐art HXrsquos bull Eliminate 90 of the joints in a 3‐ton residential AC heat pump system
bull Develop designs that could be mass produced
Target Market and Audience Heat Pumps and Air Conditioners ndash 31 of end energy use in residential and commercial buildings in 2014
Impact of Project a) New SHX concepts with reduced leakage potential ndash Year 1 b) New tooling and manufacturing approaches ndash Years 1 2 c) SHX Design amp Optimization Prototype amp Validation ndash Year 2 d) Commercialization Plan ndash Year 3 e) Heat Pumps with reduced leakage potential ndash 2‐3 Years after project
3
Approach
Develop SHX for
HVACampR ndash Reduce Leakage
Define Baseline and
Target performance
Design Concepts
Investigation CFD Analyses
Manufacturing Solutions
Investigation
HX Selection Multi‐Physics
Analysis System Performance (VapCycreg)
Tooling Development
Prototyping Validation (wind
tunnel) System Performance
Assessment
Commer‐cialization
Plan
Design Optimization
Optimizer
CFD
CoilDesignerreg
Activities (RampD)Key
Output
Key Output
Short-Term Outcome
MidLong -Term
Outcome
Automated Parameterization
4
Progress and Accomplishments ‐ Tasks amp Milestones
Task Milestone Time frame
Status
Task 11 Baseline Selection
Milestone 11 Provide details of selected baseline systems and heat exchangers and provide rationale for selection
1016 ndash 1116
Baseline selected Carrier state‐of‐the‐art 3Ton unit
CoilDesignerreg verification
Task 12 Initial Performance Simulations
Milestone 12 Demonstrate that a non‐optimized enhanced ldquodog‐bonerdquo type fin can achieve heat transfer and pressure drop
performance within 20 of the baseline fin through CFD simulations
1116 ‐0217
CoilDesignerreg optimization studies
Challenges identification Baseline re‐designed with
ldquodog‐bonerdquo fin + CFD simulations
CoilDesignerreg verification lt20 of baseline performance
5
Baseline Selection
56deg
Inner grooved
6
Baseline Selection ndash Performance Assessment VapCycreg System Results
System COP 46 ‐Power Consumption 2234 W Refrigerant Charge 148 kg
Subcooling 55 K Superheat 40 K
CoilDesignerreg Heat Exchanger Results Unit
Baseline Indoor HX
Outdoor HX
Capacity kW 1031 1258 Air flow rate cfm 1200 3149 Pressure kPa 1147 2798 Inlet Temperature K 285 345 Inlet Quality ‐ 0228 ‐Air Pressure Drop Pa 458 122 Air Heat Transfer Coefficient Wmsup2K 1013 1081
Refrigerant Pressure Drop kPa 149 233
7
Initial Analysis ndash Circuiting vs Joint Reduction
200
300
400
500
600
700
800
900
1000
SHX Joint R
eductio
n
Indoor Outdoor
Indoor baseline 4 circuits 72 joints
Outdoor baseline 5 circuits 28 joints
85
1 2 3 4 5 6 7 8 9 10 Number of SHX Circuits (‐)
8
Initial Analysis ‐ Ref ΔP vs Ndeg circuits (Indoor HX)
9
~2x baseline
Baseline
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Project Summary
Timeline Start date 102016
Planned end date 102019
Key Milestones 1 Develop Optimized Fin Geometry 082017
2 Construct Prototype Heat Exchangers 032018
3 Commercialization Plan 102019
Budget Total Project $ to Date 2393797 bull DOE $1788440 bull Cost Share $605357
Total Project $ 663397 bull DOE $509563 bull Cost Share $153834
Key Partners Optimized Thermal Systems Inc
Heat Transfer Technologies (HTT)
United Technologies Research Center (UTRC)
Project Outcome Conceptualize serpentine heatexchangers for HVAC application aiming leakage reduction Design amp Optimize novel ldquodog-bonerdquo fin concepts that result in equivalent orbetter performance than current state-ofshythe-art tube-fin heat exchangers Prototype validate and commercialize
2
Purpose and Objectives
Problem Statement develop heat exchanger design and manufacturing solutions aiming to significantly reduce the direct and indirect impacts of refrigerant leakage in heating ventilating air conditioning and refrigeration (HVACampR) systems
Main Objectives bull Develop serpentine heat exchangers (SHX) with equivalent or better performance than
current state‐of‐the‐art HXrsquos bull Eliminate 90 of the joints in a 3‐ton residential AC heat pump system
bull Develop designs that could be mass produced
Target Market and Audience Heat Pumps and Air Conditioners ndash 31 of end energy use in residential and commercial buildings in 2014
Impact of Project a) New SHX concepts with reduced leakage potential ndash Year 1 b) New tooling and manufacturing approaches ndash Years 1 2 c) SHX Design amp Optimization Prototype amp Validation ndash Year 2 d) Commercialization Plan ndash Year 3 e) Heat Pumps with reduced leakage potential ndash 2‐3 Years after project
3
Approach
Develop SHX for
HVACampR ndash Reduce Leakage
Define Baseline and
Target performance
Design Concepts
Investigation CFD Analyses
Manufacturing Solutions
Investigation
HX Selection Multi‐Physics
Analysis System Performance (VapCycreg)
Tooling Development
Prototyping Validation (wind
tunnel) System Performance
Assessment
Commer‐cialization
Plan
Design Optimization
Optimizer
CFD
CoilDesignerreg
Activities (RampD)Key
Output
Key Output
Short-Term Outcome
MidLong -Term
Outcome
Automated Parameterization
4
Progress and Accomplishments ‐ Tasks amp Milestones
Task Milestone Time frame
Status
Task 11 Baseline Selection
Milestone 11 Provide details of selected baseline systems and heat exchangers and provide rationale for selection
1016 ndash 1116
Baseline selected Carrier state‐of‐the‐art 3Ton unit
CoilDesignerreg verification
Task 12 Initial Performance Simulations
Milestone 12 Demonstrate that a non‐optimized enhanced ldquodog‐bonerdquo type fin can achieve heat transfer and pressure drop
performance within 20 of the baseline fin through CFD simulations
1116 ‐0217
CoilDesignerreg optimization studies
Challenges identification Baseline re‐designed with
ldquodog‐bonerdquo fin + CFD simulations
CoilDesignerreg verification lt20 of baseline performance
5
Baseline Selection
56deg
Inner grooved
6
Baseline Selection ndash Performance Assessment VapCycreg System Results
System COP 46 ‐Power Consumption 2234 W Refrigerant Charge 148 kg
Subcooling 55 K Superheat 40 K
CoilDesignerreg Heat Exchanger Results Unit
Baseline Indoor HX
Outdoor HX
Capacity kW 1031 1258 Air flow rate cfm 1200 3149 Pressure kPa 1147 2798 Inlet Temperature K 285 345 Inlet Quality ‐ 0228 ‐Air Pressure Drop Pa 458 122 Air Heat Transfer Coefficient Wmsup2K 1013 1081
Refrigerant Pressure Drop kPa 149 233
7
Initial Analysis ndash Circuiting vs Joint Reduction
200
300
400
500
600
700
800
900
1000
SHX Joint R
eductio
n
Indoor Outdoor
Indoor baseline 4 circuits 72 joints
Outdoor baseline 5 circuits 28 joints
85
1 2 3 4 5 6 7 8 9 10 Number of SHX Circuits (‐)
8
Initial Analysis ‐ Ref ΔP vs Ndeg circuits (Indoor HX)
9
~2x baseline
Baseline
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Purpose and Objectives
Problem Statement develop heat exchanger design and manufacturing solutions aiming to significantly reduce the direct and indirect impacts of refrigerant leakage in heating ventilating air conditioning and refrigeration (HVACampR) systems
Main Objectives bull Develop serpentine heat exchangers (SHX) with equivalent or better performance than
current state‐of‐the‐art HXrsquos bull Eliminate 90 of the joints in a 3‐ton residential AC heat pump system
bull Develop designs that could be mass produced
Target Market and Audience Heat Pumps and Air Conditioners ndash 31 of end energy use in residential and commercial buildings in 2014
Impact of Project a) New SHX concepts with reduced leakage potential ndash Year 1 b) New tooling and manufacturing approaches ndash Years 1 2 c) SHX Design amp Optimization Prototype amp Validation ndash Year 2 d) Commercialization Plan ndash Year 3 e) Heat Pumps with reduced leakage potential ndash 2‐3 Years after project
3
Approach
Develop SHX for
HVACampR ndash Reduce Leakage
Define Baseline and
Target performance
Design Concepts
Investigation CFD Analyses
Manufacturing Solutions
Investigation
HX Selection Multi‐Physics
Analysis System Performance (VapCycreg)
Tooling Development
Prototyping Validation (wind
tunnel) System Performance
Assessment
Commer‐cialization
Plan
Design Optimization
Optimizer
CFD
CoilDesignerreg
Activities (RampD)Key
Output
Key Output
Short-Term Outcome
MidLong -Term
Outcome
Automated Parameterization
4
Progress and Accomplishments ‐ Tasks amp Milestones
Task Milestone Time frame
Status
Task 11 Baseline Selection
Milestone 11 Provide details of selected baseline systems and heat exchangers and provide rationale for selection
1016 ndash 1116
Baseline selected Carrier state‐of‐the‐art 3Ton unit
CoilDesignerreg verification
Task 12 Initial Performance Simulations
Milestone 12 Demonstrate that a non‐optimized enhanced ldquodog‐bonerdquo type fin can achieve heat transfer and pressure drop
performance within 20 of the baseline fin through CFD simulations
1116 ‐0217
CoilDesignerreg optimization studies
Challenges identification Baseline re‐designed with
ldquodog‐bonerdquo fin + CFD simulations
CoilDesignerreg verification lt20 of baseline performance
5
Baseline Selection
56deg
Inner grooved
6
Baseline Selection ndash Performance Assessment VapCycreg System Results
System COP 46 ‐Power Consumption 2234 W Refrigerant Charge 148 kg
Subcooling 55 K Superheat 40 K
CoilDesignerreg Heat Exchanger Results Unit
Baseline Indoor HX
Outdoor HX
Capacity kW 1031 1258 Air flow rate cfm 1200 3149 Pressure kPa 1147 2798 Inlet Temperature K 285 345 Inlet Quality ‐ 0228 ‐Air Pressure Drop Pa 458 122 Air Heat Transfer Coefficient Wmsup2K 1013 1081
Refrigerant Pressure Drop kPa 149 233
7
Initial Analysis ndash Circuiting vs Joint Reduction
200
300
400
500
600
700
800
900
1000
SHX Joint R
eductio
n
Indoor Outdoor
Indoor baseline 4 circuits 72 joints
Outdoor baseline 5 circuits 28 joints
85
1 2 3 4 5 6 7 8 9 10 Number of SHX Circuits (‐)
8
Initial Analysis ‐ Ref ΔP vs Ndeg circuits (Indoor HX)
9
~2x baseline
Baseline
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Approach
Develop SHX for
HVACampR ndash Reduce Leakage
Define Baseline and
Target performance
Design Concepts
Investigation CFD Analyses
Manufacturing Solutions
Investigation
HX Selection Multi‐Physics
Analysis System Performance (VapCycreg)
Tooling Development
Prototyping Validation (wind
tunnel) System Performance
Assessment
Commer‐cialization
Plan
Design Optimization
Optimizer
CFD
CoilDesignerreg
Activities (RampD)Key
Output
Key Output
Short-Term Outcome
MidLong -Term
Outcome
Automated Parameterization
4
Progress and Accomplishments ‐ Tasks amp Milestones
Task Milestone Time frame
Status
Task 11 Baseline Selection
Milestone 11 Provide details of selected baseline systems and heat exchangers and provide rationale for selection
1016 ndash 1116
Baseline selected Carrier state‐of‐the‐art 3Ton unit
CoilDesignerreg verification
Task 12 Initial Performance Simulations
Milestone 12 Demonstrate that a non‐optimized enhanced ldquodog‐bonerdquo type fin can achieve heat transfer and pressure drop
performance within 20 of the baseline fin through CFD simulations
1116 ‐0217
CoilDesignerreg optimization studies
Challenges identification Baseline re‐designed with
ldquodog‐bonerdquo fin + CFD simulations
CoilDesignerreg verification lt20 of baseline performance
5
Baseline Selection
56deg
Inner grooved
6
Baseline Selection ndash Performance Assessment VapCycreg System Results
System COP 46 ‐Power Consumption 2234 W Refrigerant Charge 148 kg
Subcooling 55 K Superheat 40 K
CoilDesignerreg Heat Exchanger Results Unit
Baseline Indoor HX
Outdoor HX
Capacity kW 1031 1258 Air flow rate cfm 1200 3149 Pressure kPa 1147 2798 Inlet Temperature K 285 345 Inlet Quality ‐ 0228 ‐Air Pressure Drop Pa 458 122 Air Heat Transfer Coefficient Wmsup2K 1013 1081
Refrigerant Pressure Drop kPa 149 233
7
Initial Analysis ndash Circuiting vs Joint Reduction
200
300
400
500
600
700
800
900
1000
SHX Joint R
eductio
n
Indoor Outdoor
Indoor baseline 4 circuits 72 joints
Outdoor baseline 5 circuits 28 joints
85
1 2 3 4 5 6 7 8 9 10 Number of SHX Circuits (‐)
8
Initial Analysis ‐ Ref ΔP vs Ndeg circuits (Indoor HX)
9
~2x baseline
Baseline
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Progress and Accomplishments ‐ Tasks amp Milestones
Task Milestone Time frame
Status
Task 11 Baseline Selection
Milestone 11 Provide details of selected baseline systems and heat exchangers and provide rationale for selection
1016 ndash 1116
Baseline selected Carrier state‐of‐the‐art 3Ton unit
CoilDesignerreg verification
Task 12 Initial Performance Simulations
Milestone 12 Demonstrate that a non‐optimized enhanced ldquodog‐bonerdquo type fin can achieve heat transfer and pressure drop
performance within 20 of the baseline fin through CFD simulations
1116 ‐0217
CoilDesignerreg optimization studies
Challenges identification Baseline re‐designed with
ldquodog‐bonerdquo fin + CFD simulations
CoilDesignerreg verification lt20 of baseline performance
5
Baseline Selection
56deg
Inner grooved
6
Baseline Selection ndash Performance Assessment VapCycreg System Results
System COP 46 ‐Power Consumption 2234 W Refrigerant Charge 148 kg
Subcooling 55 K Superheat 40 K
CoilDesignerreg Heat Exchanger Results Unit
Baseline Indoor HX
Outdoor HX
Capacity kW 1031 1258 Air flow rate cfm 1200 3149 Pressure kPa 1147 2798 Inlet Temperature K 285 345 Inlet Quality ‐ 0228 ‐Air Pressure Drop Pa 458 122 Air Heat Transfer Coefficient Wmsup2K 1013 1081
Refrigerant Pressure Drop kPa 149 233
7
Initial Analysis ndash Circuiting vs Joint Reduction
200
300
400
500
600
700
800
900
1000
SHX Joint R
eductio
n
Indoor Outdoor
Indoor baseline 4 circuits 72 joints
Outdoor baseline 5 circuits 28 joints
85
1 2 3 4 5 6 7 8 9 10 Number of SHX Circuits (‐)
8
Initial Analysis ‐ Ref ΔP vs Ndeg circuits (Indoor HX)
9
~2x baseline
Baseline
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Baseline Selection
56deg
Inner grooved
6
Baseline Selection ndash Performance Assessment VapCycreg System Results
System COP 46 ‐Power Consumption 2234 W Refrigerant Charge 148 kg
Subcooling 55 K Superheat 40 K
CoilDesignerreg Heat Exchanger Results Unit
Baseline Indoor HX
Outdoor HX
Capacity kW 1031 1258 Air flow rate cfm 1200 3149 Pressure kPa 1147 2798 Inlet Temperature K 285 345 Inlet Quality ‐ 0228 ‐Air Pressure Drop Pa 458 122 Air Heat Transfer Coefficient Wmsup2K 1013 1081
Refrigerant Pressure Drop kPa 149 233
7
Initial Analysis ndash Circuiting vs Joint Reduction
200
300
400
500
600
700
800
900
1000
SHX Joint R
eductio
n
Indoor Outdoor
Indoor baseline 4 circuits 72 joints
Outdoor baseline 5 circuits 28 joints
85
1 2 3 4 5 6 7 8 9 10 Number of SHX Circuits (‐)
8
Initial Analysis ‐ Ref ΔP vs Ndeg circuits (Indoor HX)
9
~2x baseline
Baseline
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Baseline Selection ndash Performance Assessment VapCycreg System Results
System COP 46 ‐Power Consumption 2234 W Refrigerant Charge 148 kg
Subcooling 55 K Superheat 40 K
CoilDesignerreg Heat Exchanger Results Unit
Baseline Indoor HX
Outdoor HX
Capacity kW 1031 1258 Air flow rate cfm 1200 3149 Pressure kPa 1147 2798 Inlet Temperature K 285 345 Inlet Quality ‐ 0228 ‐Air Pressure Drop Pa 458 122 Air Heat Transfer Coefficient Wmsup2K 1013 1081
Refrigerant Pressure Drop kPa 149 233
7
Initial Analysis ndash Circuiting vs Joint Reduction
200
300
400
500
600
700
800
900
1000
SHX Joint R
eductio
n
Indoor Outdoor
Indoor baseline 4 circuits 72 joints
Outdoor baseline 5 circuits 28 joints
85
1 2 3 4 5 6 7 8 9 10 Number of SHX Circuits (‐)
8
Initial Analysis ‐ Ref ΔP vs Ndeg circuits (Indoor HX)
9
~2x baseline
Baseline
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Initial Analysis ndash Circuiting vs Joint Reduction
200
300
400
500
600
700
800
900
1000
SHX Joint R
eductio
n
Indoor Outdoor
Indoor baseline 4 circuits 72 joints
Outdoor baseline 5 circuits 28 joints
85
1 2 3 4 5 6 7 8 9 10 Number of SHX Circuits (‐)
8
Initial Analysis ‐ Ref ΔP vs Ndeg circuits (Indoor HX)
9
~2x baseline
Baseline
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Initial Analysis ‐ Ref ΔP vs Ndeg circuits (Indoor HX)
9
~2x baseline
Baseline
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Indoor HX) Semi‐cross Parallel Semi‐cross Counter
dS
tP
D
09
085
08
075 o
07 Full‐cross Counter
dS
tP
oD
065
Area
Red
uctio
n Factor
(‐)
06 1 155 21 265 32
PtDo (‐)
10
dS
tP
oD
087 l tP P
100 l tP P
115 l tP P
Vertical Diagonal
075 l tP P
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Initial Analysis ndash Fin ldquodog‐bonerdquo cut (Outdoor HX)
Airflow
Area
redu
ction factor
(‐)
Minimum free flow area high u
Wake flow low u
Reduced
Type 1 Type 2
095
09
085
08
075
07
065
06
Type 1 (PlPt = 087)
Type 1 (PlPt = 1)
Type 1 (PlPt = 115)
Type 2 (PlPt = 087)
Type 2 (PlPt = 1)
Type 2 (PlPt = 115)
1 122 144 166 188 21 232 254 276 298 32
PtDo (‐)
No enhancements enhancements reduction
11
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Initial Analysis ndash Manufacturing Considerations
bull Tubes ndash Minimum diameter 50mm
ndash Minimum bend radius (Do) 15
ndash Tube length NA
ndash Pitch angle NA
bull Fins ndash Minimum tube‐fin enhancement distance 20mm
ndash Max fin density ~20 FPI ndash Assembly could potentially damage enhancements yet to be
confirmed
12
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Baseline Modification ndash Indoor HX
CFD Settings bull Mesh size 10mm (polyhedral elements) bull Boundary layer 30mm 10 layers 12 growth bull Uncertainty analysis ‐ GCI (on going task) bull Dry air ndash ideal gas bull K‐e Realizable turbulence model bull B C uniform inlet velocitytemperature constant wall temp bull Steady‐State
13
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Milestone 12 Accomplishment ndash Indoor HX Metric Unit Baseline SHX‐POF‐001 Rel Diff Do m 00098 00098 000
Pl m 0019 00198 421
Pt m 00254 00254 000
Sd m 00229 00235 293
FPI m 16 16 000
Nbanks ‐ 3 3 000
Nrows ‐ 24 24 000
Ncircuits ‐ 4 4 000
Face area msup2 0263 0263 00
Joints ‐ 72 8 ‐8889
hair Wmsup2K 1011 1133 1207
Ao msup2 1685 1424 ‐1547
ΔPair Pa 4582 4969 845
ΔPref kPa 14925 14661 ‐177
Q W 10351 10187 ‐158
lt 20
Wang et al (2001) CFD
14
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Project Integration and Collaboration
OTS bull Concept
bull Design amp Opt bull Testing
HTT bull Manuf Solutions constraints
UTRC bull State‐of‐the‐
art tech bull Products
Market
Voss (Fin) ‐ NDA Brazeway (tubes) ‐
NDA
Weekly Interaction
Frequent Interaction (on demand)
bull Novel designs (Intellectual Property) bull Prototypes bull Validation bull Publications Patents technical articles
15
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Next Steps and Future Plans
bull Task 12 Initial Performance Analysis bull Finalize CFD analyses (uncertainty analysis outdoor HX)
bull Task 13 Material Simulation and Selection bull Study other modifications to the baseline to make it
manufacturable bull Indoor coil review copper and aluminum options bull Outdoor coil exploring options (Task 12) bull HTT begins exploring material and manufacturing options
bull Task 14 Benchtop Testing of Brazing Methods (HTT)
16
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
REFERENCE SLIDES
17
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Project Budget
Budget History
102016 ndash FY 2017 FY 2018 FY 2019 ndash 102019
DOE Cost‐share DOE Cost‐share DOE Cost‐share $100432 $25297 $253488 $68230 $155643 $60307
18
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
Project Plan and Schedule Project Schedule Project Start 102016 Completed Work Projected End 102019 Active Task (in progress work)
MilestoneDeliverable (Originally Planned) MilestoneDeliverable (Actual) FY2017 FY2018 FY2019
Task
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Q1 (Oct‐Dec)
Q2 (Ja
n‐Mar)
Q3 (Apr‐Jun)
Q4 (Jul‐Sep)
Past Work 10 Intellectual Property (IP) Management Plan 21 Baseline Selection 22 Initial Performance Simulations CurrentFuture Work 23 Material Simulation and Selection 24 Benchtop Testing of Brazing Methods 31 Optimization Definition and Manufacturing Considerations 32 Develop Optimized Fin Geometry 41 Design Fin Tooling 42 Construct Prototype Heat Exchangers 51 Heat Exchanger Performance Testing 52 Mechanical Cyclic Testing 61 Improve Manufacturing Techniques in Preparation for Commercialization 62 System Level Integration 63 System Level Testing 70 Develop Technology to Market Commercialization Plan
19
top related