液氮温区大功率斯特林型脉管制冷机回热器温度不均匀性及性能优化研究
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摘要
液氮温区大功率低温制冷机在能源电力、国防军事、气体液化、医疗、交通运输和低温物理等领域有着重要应用。斯特林型脉管制冷机具有可靠、高效、紧凑、轻质等突出优点,可望满足日益增长的高温超导应用要求,因此逐渐成为低温制冷机领域的研究热点。近年来,大功率斯特林型脉管制冷机虽然已取得一定进展,但是与商业化的大功率低温制冷机如G-M制冷机和斯特林制冷机相比在制冷效率和稳定性上仍有不少差距。研究表明大功率脉管制冷机并非小功率脉管制冷机的简单放大,回热器内的温度与流动不均匀性、大功率换热器设计等仅属于大功率斯特林脉管制冷机的复杂科学问题严重制约了其发展。本文将以进一步提高脉管制冷机在液氮温区的制冷性能为目标,着重研究大尺寸、大功率高频回热器的传热与流动特性,揭示回热器温度不均匀的形成及损失机理,探索在高频大功率条件下实现高效回热的方法,进而提高脉管制冷机在液氮温区的制冷效率,最终为拓展低温制冷机的大规模工业应用奠定基础。为此本文开展了以下三方面的理论和实验的研究工作：
1.开发了液氮温区单级大功率斯特林型脉管制冷机数值模拟程序,并对大功率斯特林型脉管制冷机工作机理进行了深入的理论分析：
为了更全面、正确地把握大尺寸、大功率高频脉管制冷机的制冷及损失机理,本文基于数值软件Sage建立了单级大功率斯特林型脉管制冷整机模型,在仿真计算基础上研究了回热器、脉管等主要部件的几何尺寸,回热器填料等对制冷机内部传热流动特性与制冷性能的影响。为提高制冷机效率,大功率斯特林型脉管制冷机应采用小长径比的回热器,以保证声功耗散能力的同时减少流阻损失。制冷温度越高,以制冷量为优化目标所对应的最佳回热器长度越短,因此本文对回热器长度进行优化从而提升制冷机在液氮温区的制冷性能。另外,分析了充气压力和运行频率对制冷性能的影响,可为单级斯特林型脉管制冷机的性能优化提供参考。经模拟计算,制冷机能达到31.5K的最低无负荷制冷温度,在80K可以获得508W制冷量。
2.对大功率脉管制冷机回热器温度不均匀性进行了理论研究,推导了回热器温度不均匀性引起的相对直流解析式,发展了并联回热器整机数值模拟程序：
回热器温度不均匀性造成了严重的直流损失,制约了大功率脉管制冷机的性能优化。本文对回热器内温度不均匀性产生的机理,对回热器性能的影响以及抑制方法进行了系统归纳和总结。回热器内微弱的直流即可诱发回热器内径向温度不均匀性,而径向温度不均匀性又会进一步促进直流的产生。基于热力学理论推导了回热器内相对直流解析式。指出不均匀孔隙率或径向温度分布均可以导致直流的产生,另外对轴向温度梯度、回热器长度、回热器填料特性和充气压力等对回热器内直流的影响进行了分析。建立了并联回热器数值模拟程序讨论了不均匀孔隙率对回热器温度不均匀性和制冷性能的影响,为进一步抑制回热器直流损失,优化制冷机性能提供了理论指导。
3.发展了回热器高热导率复合填料结构,深入研究了其工作机制,在此基础上对复合填料的结构进行了优化：
为抑制大功率斯特林型脉管制冷机回热器内的温度不均匀性,减小回热器直流损失,提出了回热器高热导率复合填料结构,将原有的部分不锈钢丝网替换为具有更高热导率的紫铜或黄铜填料。对比研究了七种不同的回热器高热导率复合填料,实验结果表明强化回热器填料径向导热对于抑制回热器内温度不均匀性具有显著作用。通过优化复合填料结构,斯特林型脉管制冷机可以达到41.3K的最低无负荷制冷温度。在8.9kW输入功率下78.2K可以提供424.5W制冷量,相对卡诺效率为13.5%,这是目前国内公开报道的同类脉管制冷机最好水平。
Cryocoolers working at liquid nitrogen temperatures have played important role in the fields of power grids, military, medical applications, transportation and low-temperature physics. The Stirling pulse tube cryocooler (SPTC) has a high potential to fulfill the increasing demands of High temperature superconducting (HTS) applications due to its advantages of high reliability, high efficiency, compactness, and low mass, thus gradually become a hot topic in the filed of cryocooler. The high power SPTC has already made some progress in the past few years. Nevertheless, comparing with the commercial high power cryocooler like G-M cooler and Stirling cooler, the SPTC has still to be further improved both on efficiency and reliability. Extending SPTCs to high cooling capacity is not a simple matter of scaling up the existing small-scale SPTCs. There are several stubborn problems only related to high power SPTCs, such as flow inhomogeneity and temperature inhomogeneity in the regenerator, impedance matching between compressor and cooler, the design of high power heat exchanger. These problems restrict the developments of high power SPTCs. With the aim of further improving the cooling performance of SPTC working at liquid nitrogen temperatures, in this paper, the flow and heat transfer characteristics of large-scale high power high frequency regenerators has been studied, the mechanism of temperature non-uniformity and related losses in the regenerator has been revealed, the methods to realize high efficient regeneration under the condition of high power and high frequency has been investigated. Based on the efforts listed above, the cooling efficiency of SPTC working at liquid temperatures is supposed to be improved, thus to brandly extend the use of cryocoolers in industry applications. In this paper, the theoretical and experimental research include three parts as listed below:
1. Developed a numerical model of single-stage high power SPTC working at liquid nitrogen temperatures, and further investigated the working mechanism of high power SPTC:
In order to fully and correctly understand the refrigeration and losses mechanism of large scale high power SPTC. A single stage SPTC numerical model was established based on simulation software Sage. The influence of regenerator and pulse tube dimensions together with regenerator matrix on the flow and heat transfer characteristics inside the SPTC were investigated on the basis of simulation. The high power SPTCs are supposed to adopt regenerators with small length to diameter ratio in order to guarantee the dissipation ability of acoustic power and simultaneously reduce the friction losses. The higher the refrigeration temperature is, the shorter the optimum regenerator is with respect to the object of cooling power. Therefore, the length of regenerator was optimized in this paper to improve the cooling performance at liquid nitrogen temperatures. Moreover, the effect of charge pressure and operating frequency on the cooling performance was also studied to guide the experimentally optimization of SPTC. Based on calculation, the SPTC can reach a no-load refrigeration temperature of31.5K and provide a cooling power of508W at80K.
2. Theoretically investigated the temperature non-uniformity in the regenerator of SPTC, derived the analytical governing equation of relative DC flow caused by temperature non-uniformity, and developed a simulation model with parallel regenerators to numerically study the effect of temperature non-uniformity:
Temperature non-uniformity in the regenerator will introduce significant DC flow losses, thus to reduce the cooling performance of high power SPTC. In this paper, the mechanism of temperature non-uniformity, the influence of temperature non-uniformity on the regenerator performance and the method of inhibiting temperature non-uniformity was comprehensively concluded and summarized. Theoretical study shows that even tiny DC flow occurred in the regenerator will skew the temperature profile and lead to transverse temperature non-uniformity. On the other hand, the transverse temperature non-uniformity will enlarge the amount of DC flow. Based on thermodynamic analysis, the governing equation of relative DC flow was derived. The result illustrates that either non-uniform temperature profile or porosity can generate DC flow. The effect of axial temperature gradient, the regenerator length, the regenerator matrix and charge pressure on the DC flow were also discussed. A numerical model with parallel regenerator was built to investigate the influence of non-uniformity porosity on the temperature non-uniformity and the cooling performance, which will guide the inhibition of DC flow losses and improvement of cooling performance.
3. Developed the hybrid regenerator fillings with enhanced thermal conductance, further investigated the working mechanism of hybrid fillings, and optimized the composition of the regenerator fillings:
In order to degrade the regenerator temperature non-uniformity in the SPTC and reduce the DC flow losses, the hybrid regenerator fillings with enhanced thermal conductance was proposed. Part of the original stainless steel screens were replaced by materials with higher thermal conductance like copper and brass. Seven different hybrid fillings were tested and compared, the experimental results revealed that the temperature non-uniformity in the regenerator was significantly reduced by enhancing the thermal conductance of regenerator fillings. By optimizing the composition of hybrid fillings, the SPTC can reach a no-load refrigeration temperature of41.3K. A cooling power of424.5W can be obtained at78.2K with an input power of8.9kW, the relative Carnot efficiency is13.5%, which is the best among the domestic reported similar SPTCs.
1.开发了液氮温区单级大功率斯特林型脉管制冷机数值模拟程序,并对大功率斯特林型脉管制冷机工作机理进行了深入的理论分析：
为了更全面、正确地把握大尺寸、大功率高频脉管制冷机的制冷及损失机理,本文基于数值软件Sage建立了单级大功率斯特林型脉管制冷整机模型,在仿真计算基础上研究了回热器、脉管等主要部件的几何尺寸,回热器填料等对制冷机内部传热流动特性与制冷性能的影响。为提高制冷机效率,大功率斯特林型脉管制冷机应采用小长径比的回热器,以保证声功耗散能力的同时减少流阻损失。制冷温度越高,以制冷量为优化目标所对应的最佳回热器长度越短,因此本文对回热器长度进行优化从而提升制冷机在液氮温区的制冷性能。另外,分析了充气压力和运行频率对制冷性能的影响,可为单级斯特林型脉管制冷机的性能优化提供参考。经模拟计算,制冷机能达到31.5K的最低无负荷制冷温度,在80K可以获得508W制冷量。
2.对大功率脉管制冷机回热器温度不均匀性进行了理论研究,推导了回热器温度不均匀性引起的相对直流解析式,发展了并联回热器整机数值模拟程序：
回热器温度不均匀性造成了严重的直流损失,制约了大功率脉管制冷机的性能优化。本文对回热器内温度不均匀性产生的机理,对回热器性能的影响以及抑制方法进行了系统归纳和总结。回热器内微弱的直流即可诱发回热器内径向温度不均匀性,而径向温度不均匀性又会进一步促进直流的产生。基于热力学理论推导了回热器内相对直流解析式。指出不均匀孔隙率或径向温度分布均可以导致直流的产生,另外对轴向温度梯度、回热器长度、回热器填料特性和充气压力等对回热器内直流的影响进行了分析。建立了并联回热器数值模拟程序讨论了不均匀孔隙率对回热器温度不均匀性和制冷性能的影响,为进一步抑制回热器直流损失,优化制冷机性能提供了理论指导。
3.发展了回热器高热导率复合填料结构,深入研究了其工作机制,在此基础上对复合填料的结构进行了优化：
为抑制大功率斯特林型脉管制冷机回热器内的温度不均匀性,减小回热器直流损失,提出了回热器高热导率复合填料结构,将原有的部分不锈钢丝网替换为具有更高热导率的紫铜或黄铜填料。对比研究了七种不同的回热器高热导率复合填料,实验结果表明强化回热器填料径向导热对于抑制回热器内温度不均匀性具有显著作用。通过优化复合填料结构,斯特林型脉管制冷机可以达到41.3K的最低无负荷制冷温度。在8.9kW输入功率下78.2K可以提供424.5W制冷量,相对卡诺效率为13.5%,这是目前国内公开报道的同类脉管制冷机最好水平。
Cryocoolers working at liquid nitrogen temperatures have played important role in the fields of power grids, military, medical applications, transportation and low-temperature physics. The Stirling pulse tube cryocooler (SPTC) has a high potential to fulfill the increasing demands of High temperature superconducting (HTS) applications due to its advantages of high reliability, high efficiency, compactness, and low mass, thus gradually become a hot topic in the filed of cryocooler. The high power SPTC has already made some progress in the past few years. Nevertheless, comparing with the commercial high power cryocooler like G-M cooler and Stirling cooler, the SPTC has still to be further improved both on efficiency and reliability. Extending SPTCs to high cooling capacity is not a simple matter of scaling up the existing small-scale SPTCs. There are several stubborn problems only related to high power SPTCs, such as flow inhomogeneity and temperature inhomogeneity in the regenerator, impedance matching between compressor and cooler, the design of high power heat exchanger. These problems restrict the developments of high power SPTCs. With the aim of further improving the cooling performance of SPTC working at liquid nitrogen temperatures, in this paper, the flow and heat transfer characteristics of large-scale high power high frequency regenerators has been studied, the mechanism of temperature non-uniformity and related losses in the regenerator has been revealed, the methods to realize high efficient regeneration under the condition of high power and high frequency has been investigated. Based on the efforts listed above, the cooling efficiency of SPTC working at liquid temperatures is supposed to be improved, thus to brandly extend the use of cryocoolers in industry applications. In this paper, the theoretical and experimental research include three parts as listed below:
1. Developed a numerical model of single-stage high power SPTC working at liquid nitrogen temperatures, and further investigated the working mechanism of high power SPTC:
In order to fully and correctly understand the refrigeration and losses mechanism of large scale high power SPTC. A single stage SPTC numerical model was established based on simulation software Sage. The influence of regenerator and pulse tube dimensions together with regenerator matrix on the flow and heat transfer characteristics inside the SPTC were investigated on the basis of simulation. The high power SPTCs are supposed to adopt regenerators with small length to diameter ratio in order to guarantee the dissipation ability of acoustic power and simultaneously reduce the friction losses. The higher the refrigeration temperature is, the shorter the optimum regenerator is with respect to the object of cooling power. Therefore, the length of regenerator was optimized in this paper to improve the cooling performance at liquid nitrogen temperatures. Moreover, the effect of charge pressure and operating frequency on the cooling performance was also studied to guide the experimentally optimization of SPTC. Based on calculation, the SPTC can reach a no-load refrigeration temperature of31.5K and provide a cooling power of508W at80K.
2. Theoretically investigated the temperature non-uniformity in the regenerator of SPTC, derived the analytical governing equation of relative DC flow caused by temperature non-uniformity, and developed a simulation model with parallel regenerators to numerically study the effect of temperature non-uniformity:
Temperature non-uniformity in the regenerator will introduce significant DC flow losses, thus to reduce the cooling performance of high power SPTC. In this paper, the mechanism of temperature non-uniformity, the influence of temperature non-uniformity on the regenerator performance and the method of inhibiting temperature non-uniformity was comprehensively concluded and summarized. Theoretical study shows that even tiny DC flow occurred in the regenerator will skew the temperature profile and lead to transverse temperature non-uniformity. On the other hand, the transverse temperature non-uniformity will enlarge the amount of DC flow. Based on thermodynamic analysis, the governing equation of relative DC flow was derived. The result illustrates that either non-uniform temperature profile or porosity can generate DC flow. The effect of axial temperature gradient, the regenerator length, the regenerator matrix and charge pressure on the DC flow were also discussed. A numerical model with parallel regenerator was built to investigate the influence of non-uniformity porosity on the temperature non-uniformity and the cooling performance, which will guide the inhibition of DC flow losses and improvement of cooling performance.
3. Developed the hybrid regenerator fillings with enhanced thermal conductance, further investigated the working mechanism of hybrid fillings, and optimized the composition of the regenerator fillings:
In order to degrade the regenerator temperature non-uniformity in the SPTC and reduce the DC flow losses, the hybrid regenerator fillings with enhanced thermal conductance was proposed. Part of the original stainless steel screens were replaced by materials with higher thermal conductance like copper and brass. Seven different hybrid fillings were tested and compared, the experimental results revealed that the temperature non-uniformity in the regenerator was significantly reduced by enhancing the thermal conductance of regenerator fillings. By optimizing the composition of hybrid fillings, the SPTC can reach a no-load refrigeration temperature of41.3K. A cooling power of424.5W can be obtained at78.2K with an input power of8.9kW, the relative Carnot efficiency is13.5%, which is the best among the domestic reported similar SPTCs.
引文
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