BRAYTON – Computational Fluid Mechanics with Experimental Validation

Recirculating flow
Skewness Factor for Various Inlet-Header Widths
(fixed exit-header width = 5.0in)

10.0%

Skewness Factor is (∆ ∆pMAX - ∆pMIN) / ∆pAVG

8.0% from linear fit to data

6.0%

4.0%
+ skewness is biased toward centerline (away from inlet)
Skewness Factor

2.0% Wh = 1.5in
Wh = 3.0in
0.0% Wh = 4.5in

-2.0%

-4.0%

-6.0% Exit flow separation

This analysis sponsored by AREVA
-8.0%
0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Reynolds Number Flow Normalized by Design Value Manometer Bank

Flow Meter

Regenerative Blower

Cell Inlet
Cell Outlet

Rigorous experimental technique – Quality of Data

 Flow distribution on rectangular slot headers
– a CFD analysis validated with experimental methods
• Counterflow heat exchangers require cross-flow headers to properly orient one or both of
the fluid streams in the counterflow matrix.
• The geometry of the inlet and exit headers introduce regions of separated flow, thickened
boundary layers, turning losses, and entrance and exit effects. These factors influence the
flow distribution within the counterflow matrix as well as the headers’ pressure loss. Due
to the complexity of the flow field, standard header design correlations are not suitable.
• The typical engineering approach is to conservatively over-size the header dimensions to
assure low losses and uniform static pressure distribution between the entering and
exiting faces of the counterflow matrix. However, increasing header width is known to
elevate thermal stresses at the interface between the matrix and the header.
• With the objective of minimizing header dimensions, Brayton has performed a series of
parametric studies on a practical header geometry. These studies quantify the flow
distribution through the counterflow matrix, predict overall pressure losses, and derive the
velocities necessary to determine local heat transfer coefficients.
• A combination of computational fluid dynamic (CFD) and controlled experimental methods
are employed to analyze the headers and optimize the geometry for acceptable levels of
stress levels, pressure losses, and flow mal-distribution.
• Though CFD is an invaluable tool, we believe that it’s results are often more qualitative
that quantitative. In most cases, experimental methods, with rigorous attention to details
is required to adjust internal turbulence models and validate CFD models
• Brayton Energy performs a full service of CFD analyses. We also take special pride in
our understanding of experimental methods and the importance of maintaining the highest
possible testing standards.