Design and Optimization of the Inlet Header Structure in Microchannel Heat Exchanger Based on Flow Distribution Uniformity

The flow distribution in a printed circuit heat exchanger (PCHE) is of great theoretical and practical significance in the Brayton cycle power generation system. For the straight barrel inlet header PCHE, when S-CO2 flows in the PCHE, the structural types and working parameters of the inlet header and diversion zone may lead to differences in the flow distribution in each channel of the PCHE. This flow distribution difference affects the thermal hydraulic characteristics of the PCHE. A numerical simulation method was applied to explore the flow uniformity of the PCHE and the overall performance and analyze the influence of the type of straight barrel inlet header PCHE. Within each layer, the flow showed an uneven flow distribution, and the optimized inlet header was the tapered type. The results showed that when the taper angle varies from 6° to 9°, the flow distribution in each layer is relatively uniform. The comprehensive heat transfer performance of the straight-channel PCHE can be improved by 17.3–19.7%. Finally, the response surface and a genetic algorithm were combined to optimize the inlet header. The heat transfer performance of the optimized PCHE was improved by 19.7%.