Entropy optimization of an additively manufactured heat exchanger with a dual stage Gifford-McMahon cryogenic refrigerator for hydrogen liquefaction

Abstract

Small-scale hydrogen liquefaction has emerged as an approach to fuel small aircraft powered by fuel cells. However, limited research on the design and optimization of small-scale hydrogen liquefiers, specifically the heat exchangers, is available. This paper describes a minimum entropy design for a heat exchanger mounted on a dual stage Gifford-McMahon cryogenic refrigerator. To minimize entropy generation the heat exchanger utilizes a bifurcating flow structure with varying wall thickness. Numerical optimization indicates that the heat exchanger will generate half of the entropy of a single coiled tube, significantly reducing the required heat exchanger length by 91.4% and the thermal mass by 43.8%. The heat exchanger was 3D printed with an aluminum alloy and the interior coated with a ruthenium-based catalyst for ortho-parahydrogen conversion. Hydrogen entering the heat exchanger near 293 K and 653 kPa is cooled to 28.1 K and full ortho-parahydrogen conversion is assumed before entering the storage dewar. The resulting experimental tests indicate a potential to increase heat exchanger efficiency in a more compact form factor, as well as a promising future for additively manufactured components in cryogenics.