Heat exchanger for alternative energy

• Eaton selected the proper material for the heat exchanger where gas temperatures could surpass 1500°C.
• Eaton constructed a test rig to withstand very high temperatures to closely approximate the application.
• Due to high operating temperatures, Eaton took radiation into account, which is often neglected in many forced airflow cooling solutions.
• Eaton researched high-temperature thermal interface materials as standard interface materials were not appropriate for this application.

Several CFD models were created and run to optimize heat exchange geometry. The final designs were presented to the customer with recommendations as to which one would be most beneficial.

Two hardware designs were selected for prototype and performance testing in Eaton’s Laconia facility. Mechanical mock-ups were used to provide the most accurate thermal properties and data throughout testing. Testing of the actual thermoelectric modules then followed.

A detailed CFD model was used to simulate the system. Using the prototypes, testing was performed to gather data. Data from the prototype was used to further refine and finalize the CFD model based on the results.

Detailed material properties investigation, coupled with CFD analysis enabled the selection of material used to withstand the generator’s high operating temperatures.

Concurrent engineering between Eaton and customer was practiced to meet engineering and timeline goals.

Eaton heat exchanger solutions