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Gas-to-gas heat exchanger design for high performance thermal energy storage

Cardenas, B.; Garvey, Seamus D.; Kantharaj, Bharath; Simpson, M.C.

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B. Cardenas

Seamus D. Garvey

Bharath Kantharaj

M.C. Simpson


The mathematical modelling and optimization of a gas-to-gas heat exchanger with a non-constant cross sectional area is presented. The design of the cross sectional area of the heat exchanger analyzed is based on an hexagonal mesh, which would be highly impractical to fabricate in a conventional way but could be built relatively easily through modern manufacturing techniques. The geometric configuration proposed allows attaining a high exergy efficiency and a significant cost reduction, measured in terms of volume per unit of exergy transfer. The relationship that exists between the overall exergy efficiency of the heat exchanger and its cost is thoroughly explained throughout the study.

The results obtained from the modelling demonstrate the premise that it is possible to realize designs for heat exchangers that are highly exergy-efficient and very cheap, owing to the small volume of material required, if the constrains imposed by the limitations of traditional manufacturing methods are set aside. Furthermore, the study reveals a very important fact: the volume of material in a heat exchanger increases in quadratic proportion to its characteristic dimension, which implies that scaling up the geometry has a strong impact on its cost-effectiveness.


Cardenas, B., Garvey, S. D., Kantharaj, B., & Simpson, M. (2017). Gas-to-gas heat exchanger design for high performance thermal energy storage. Journal of Energy Storage, 14(2),

Journal Article Type Article
Acceptance Date Mar 1, 2017
Online Publication Date Mar 18, 2017
Publication Date Dec 1, 2017
Deposit Date Aug 16, 2017
Publicly Available Date Aug 16, 2017
Journal Journal of Energy Storage
Electronic ISSN 2352-152X
Publisher Elsevier
Peer Reviewed Peer Reviewed
Volume 14
Issue 2
Keywords Air to air heat exchanger; High exergy efficiency; Non-constant cross sectional area; Additive manufacturing; Cost optimization
Public URL
Publisher URL


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