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38 Chapter 3 Heat exchanger design and construction upper plate shows the over etching of the outer edge in the time allowed for etchant impregnation through holes in the photo-resist that are too small. The smallest hole diameter and hole spacing which gave defect free plates were 1mm and 1.7mm. The thinnest rigid sheet of PCB laminate commercially available was 0.79mm thiclc. A typical plate and spacer used in the construction of the MHE are shown in Plate 3.3. The Indalloy® solder paste (series NC-SMQ51, Indium Corporation of America) was screen printed using a 36T mesh screen and 70 durometer hardness squeegee. Plates and spacers were held in a jig for the screen printing. The screen printing allows good control of the amount of solder deposited on each surface. The plates and spacers are stacked in another jig for holding them in place in the oven while the solder flows. A dry run (prior to being screen printed) of the stack of plates and spacers with thermocouples placed at various points in the stack was used to set the temperature-time ramp-up profile prescribed for the solder paste. The headers, which are constructed from 304 stainles's steel, were previously tinned for ease of soldering. 3.7 Optimization of MHE geometry Optimization of MHE geometry is extremely difficult because of the large number of variables. Equation (3.22) gives the surface area required for any known desired Ntu. There are 13 independent variables in this equation, and the interrelationships between these variables are extremely complex. One of the main requirements is to make the heat exchangers as small as practicable. To achieve this the surface area per unit volume must be maximised. For perforated plate if d/o<2 (perforation diameter/plate thickness) then the hole increases the surface area per unit volume. If d/o>2 then the hole reduces the surface area per unit volume. This has surprisingly never been stated previously in any of the perforated plate MHE related literature. The method used to fabricate MHE's for this work, as described in section 3.6, impose~ some constraints on the geometric variables. The plate thickness, minimum hole diameter and hole spacing, spacer thickness, and plate and spacer conductivity were determined by process limitations and material availability. Hole diameter to plate thickness ratio was two (d/o=2). Fluid flow rate and property related variables are predefined in this case. Gross geometry variables: flow channel width, fin height and spacer dimensions were the only variables that needed to be defined for optimal performance. Optimization of MHE geometry was done by using an exhaustive search to minimize a Goodness factor. The factor used was a weighted combination of MHE volume, number ofplates and pressure drop. The weightings reduced the numbers to the same order of magnitude so that their contribution to the Goodness factor was even. APDF Image | CO2 removal from air for alkaline fuel cells operating with liquid H2
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