DOE OSTI2025
Convective heat transfer characteristics and theoretical thermal stress behaviors are numerically calculated using RELAP5-3D for the helical-coiled once-through steam generator (H-OTSG) and the novel heat exchanger design known as the oval-twisted helically coiled heat exchanger (OTHCHX) under (1) fluctuating wall temperature conditions, (2) square-wave pulsating flow conditions, and (3) the combined effects of fluctuating wall temperature and square-wave pulsating flow conditions. Heat transfer coefficient models for the H-OTSG and OTHCHX were developed based on existing data and implemented into RELAP5-3D, successfully capturing the Nuavg behavior within 8% to 10% of the reported data. Under fluctuating wall temperature conditions, the OTHCHX displayed higher Nu avg behavior than the H-OTSG. As 𝑓 increased, the $𝜎^{𝑚𝑎𝑥}_{𝑡ℎ}$ decreased. The $𝜎^{𝑚𝑎𝑥}_{𝑡ℎ}$ was higher for the OTHCHX than for the H-OTSG under fluctuating wall temperature conditions. Under pulsating flow conditions, the H-OTSG and OTHCHX displayed much higher 𝑁𝑢 𝑎𝑣𝑔 than under constant flow conditions. The H-OTSG displayed a higher $𝜎^{𝑚𝑎𝑥}_{𝑡ℎ}$ over the OTHCHX. Under combined fluctuating wall temperature and pulsating flow conditions, the augmented heat transfer behavior from the pulsating flow was counteracted by the wall temperature fluctuations, producing slightly higher 𝑁𝑢 𝑎𝑣𝑔 over constant wall temperature, constant flow conditions, but much lower than only constant pulsating flow under constant wall temperature conditions. The effects of simultaneous wall temperature fluctuations and square-wave pulsating flow caused higher $𝜎^{𝑚𝑎𝑥}_{𝑡ℎ}$ than that of only wall temperature fluctuations or pulsating flow. As the Reynolds number (Re) increased, $𝜎^{𝑚𝑎𝑥}_{𝑡ℎ}$ increased. However, when 𝑓=𝑓$_{\dot{m}}$, the $𝜎^{𝑚𝑎𝑥}_{𝑡ℎ}$ showed decreasing values as Re increased. In conclusion, the results indicate that thermal-fluid resonance can help mitigate thermal stresses.