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A Compact Lightweight Gas-Turbine Regenerator

Douglas Stephen Beck

Creare Incorporated
Hanover, New Hampshire

ABSTRACT h specific enthalpy (J/kg)

This paper describes a new kind of gas-turbine h convective-heat-transfer coefficient (W/m 2-K)
regenerator, the Creare Baleen Regenerator. The Baleen (hA) convective conductance (W/K)
Regenerator is much more compact and lightweight than (hA)' convective-conductance ratio (—)
current regenerators and recuperators. These features make the k thermal conductivity (W/m-K)
Baleen Regenerator attractive for regenerative gas turbines for L core thickness or flow length (m)
aircraft, power generation, marine propulsion, and automobiles.
mR mass of core (kg)
In addition to a description of the Baleen Regenerator, this
rim mass-flow rate (kg/s)
paper also gives a design method with which the Baleen
Regenerator and other regenerators can be designed directly iii, , carry-over leakage (kg/s)
from input specifications. This design method is illustrated NSLATS number of slats (—)
with designs of the Baleen Regenerator for a 20 MW gas
NTU t , number of transfer units (—)
turbine and a 3 MW gas turbine. CNE 1/(hA).. +t/(hA)xI

Nu Nusselt number, hD H/k (—)

NOMENCLATURE p core porosity, void volume divided by total

Ah heat-transfer area (m 2 ) volume (—)
As solid area of the core (m 2 ) PVOL average porosity over the entire core volume (—)
As' solid-area ratio, the ratio of the solid area on the P pressure (Pa)
air side to that on the exhaust side (—) R radius (m)
s slat spacing (m)
ATOT total core area normal to the flow(m 2 )
SC seal coverage, the fraction of the core face area
Cf friction coefficient (—)
covered by seals (—)
cP specific heat capacity calculated at the average
t slat thickness (m)
temperature on the indicated side (J/kg-K)
T temperature (K)
C heat-capacity rate (W/K) VR core volume (m 3 )
C RT heat-capacity-rate ratio (—) V, void volume under one seal (m 3 )
CROT dimensionless core-rotation rate (—) V volumetric-flow rate (m 3/s)
CC core compactness (m')
V' core-volume ratio (—)
DH hydraulic diameter (m)
wR core width (m)
IF fuel-air ratio (—)
ws width of a seal (m)

Presented at the International Gas Turbine and Aeroengine Congress and Exposition
Houston, Texas - June 5-8, 1995
Greek Nomenclature Kays and London (1984) list three advantages that
regenerators have over recuperators:
(AP) pressure drop (Pa) (1) A much more compact heat-transfer surface can be
s effectiveness (–) employed.
K permeability (m 2 ) (2) The heat-transfer surface is substantially less
X core-conduction parameter (–) expensive per unit of transfer area.
µ viscosity (kglm-s) (3) Because of the periodic flow reversals, there are no

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p density (kg/m 3 )
tiROT core-rotation period (s)
Subscripts
c compressor
i inlet
N on the side of minimum heat-capacity rate
0 outlet
R of the core material
X on the side of maximum heat-capacity rate
1 INTRODUCTION
Heat exchangers are used in gas-turbine systems to
recover otherwise wasted heat in the exhaust and to transfer
this thermal energy to the compressed air. Regenerators and
recuperators have both been used as heat exchangers in
gas-turbine systems. Figure 1 shows how regenerators and
recuperators work. In a regenerator, the heat-transfer surface is
alternately exposed to the two flows. In a recuperator, heat is
transferred through walls that separate the flows.
permanent flow-stagnation regions and, consequently,
the surface tends to be self-cleaning. The self-
cleaning feature has been well demonstrated by
Ljungstrom-type air preheaters used in central station
plants employing the very lowest grades of coal.
A fourth advantage is that gas-turbine regenerators require
only light-gauge containment for the low-pressure exhaust
over most of their volumes. Recuperators require heavy-gauge
containment over their entire volumes. These advantages
enable regenerators to be more compact, lightweight,
inexpensive, and robust than recuperators.
Kays and London (1984) list two disadvantages of
regenerators:
(1) There is some mixing of the hot and cold fluids
because of leakage and carryover.
(2) If the fluids are at different pressures, as in the
gas-turbine regenerator, the sealing problem is a
difficult one.
Some fluid mixing is acceptable in gas-turbine systems;
however, leakages have been unacceptably high—over 4% of
the compressor flow in many cases—because seal designs have
been poor. This is why recuperators have been favored over
regenerators for gas-turbine systems.

Core
Movement

Heat Transferred
Heat Transferred
From Exhaust
♦— M, From Exhaust
—^^ To Core
To Walls

Heat Transferred /`
Seal From Walls —9.
To Compressed Air
Heat Transferred
From Core
To Compressed Air
Regenerator Recuperator

FIGURE 1. HOW REGENERATORS AND RECUPERATORS WORK

2
 Creare is developing a regenerator, the Baleen Regenerator,
that should have low leakage of the compressor flow. The
Baleen Regenerator should realize all of the advantages
regenerators have over recuperators without the seal-leakage
disadvantage. The Baleen Regenerator will be smaller, 10 times
lighter, less expensive, and more robust (due to the periodic
flow reversals) than state-of-the-art recuperators.
This paper first describes the Baleen Regenerator in
Section 2 and gives commercial applications in Section 3.
Then Section 4 describes a method with which the Baleen
Regenerator and other regenerators can be designed directly
from input specifications. Two example designs of the Baleen
Regenerator are given. Section 5 gives conclusions.
2 CREARE BALEEN REGENERATOR
Figure 2 compares schematics of the Baleen Regenerator
and a state-of-the-art plate-fin recuperator that would be equally
effective and would have identical pressure drops. We have named
the regenerator the Baleen Regenerator because the foil slats that
comprise its core resemble the baleens of whales. As Figure 2
shows, the core of the Baleen Regenerator rotates so each slat is
alternately exposed to the exhaust flow and the compressed-air
flow. During the exposure to the exhaust flow, the slats absorb heat.
During the exposure to the compressed-air flow, this thermal energy
is released to heat the compressed air.
Heat Transfe
From Exhau;
To Slats
Cool Exhaust
Out
Heat Transfer Cool
From Slats To Compressed-Air In
Compressed Air
Creare
Baleen Regenerator
Concept State-of-the-Art Recuperator
FIGURE 2. BALEEN REGENERATOR'S CORE IS 5.1 TIMES SMALLER AND 16 TIMES
LIGHTER THAN A STATE-OF-THE-ART RECUPERATOR CORE
The Baleen Regenerator's core is 1/5 the size and 1/16 the
weight of the recuperator's core. The reasons for these great
size differences stem from the fact that each plate in the
plate-fin recuperator must support the pressure difference
between the flows, but the Baleen Regenerator's slats are not
required to support any pressure difference. The slats of the
Baleen Regenerator are 0.001 inch (25 µm) thick. The plates in
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the recuperator are typically 0.008 inch (200 µm) thick to
support the pressure difference (see Wilson and Kupratis,
1994). The fact that the Baleen Regenerator's slats are thinner
has a double impact on core volume and weight. First, the
8-times-thinner slats make the core at least 8 times lighter.
Second, the thinner slats offer a smaller area for core heat
conduction in the flow direction. Conduction reduces
heat-exchanger effectiveness, so the flow length in the plate-fin
recuperator must be 4 times longer to compensate for the
effects of conduction. This means that to achieve the same
pressure drop across the core, the recuperator's plates must be
spaced twice as far apart as the Baleen Regenerator's slats.
Core compactness is inversely proportional to the square of
passage dimension, so spacing the plates twice as far apart
means that to achieve the same thermal effectiveness, the
recuperator's core must be at least 4 times as large. Core
compactness is also proportional to core porosity (void volume
divided by total volume), and the Baleen Regenerator has a
higher porosity, so the recuperator's core must be 5.1 times
Cool
'ompressed
Air In
Cool Exhaust Out
larger than the Baleen Regenerator's. All these factors make
the Baleen Regenerator's core potentially ) 1/5 the size and
1/16 the weight of the core of a recuperator with identical
performance. This means that a complete Baleen Regenerator
(including headers, ducting, etc.) would be 1/10 the weight of a
state-of-the-art recuperator.
4 BALEEN-REGENERATOR DESIGN CALCULATIONS
This section describes a method with which the Baleen
Regenerator and other regenerators can be designed directly
from input specifications. This design method is illustrated
with two designs of the Baleen Regenerator: (1) for a 20 MW
gas turbine and (2) for a 3 MW gas turbine.
Table 1 lists inputs for designing the Baleen Regenerator

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3 COMMERCIAL APPLICATIONS
The compactness and low weight of the Baleen
Regenerator make it attractive for regenerative gas turbines for
aircraft, especially for the powerplants of rotorcraft (see
Bewley, 1990). However, these features also make the Baleen
Regenerator attractive for myriad other applications including
regenerative gas turbines for land-based power generation, for
terrestrial propulsion, and for marine propulsion.
and output design dimensions. This section describes how to
calculate the dimensions from the input specifications.
The five steps in the regenerator-design calculations are:
(1) Calculate fluid properties;
(2) Calculate core performance;
(3) Calculate regenerator heat-transfer parameters;
(4) Calculate dimensionless core size (NTU); and
(5) Calculate regenerator dimensions.
The following sections describe these steps.

TABLE 1. BALEEN-REGENERATOR INPUT SPECIFICATIONS AND OUTPUT DESIGN DIMENSIONS

Inputs Units Description 20-MW GT 3-MW GT

E – Effectiveness 95% 90%
SC – Seal Coverage—Fraction of Core Face Area Occupied by Seals 10% 10%
(OP/P) x – Normalized Pressure Drop on Exhaust Side 2% 2%
rh ^ c / m e – Normalized Carry-Over Leakage 2% 2%
mN kg/s Mass-Flow Rate of Compressed Air 42 7
fx – Fuel-Air Ratio on Exhaust Side 2% 2%
TN, K Air Inlet Temperature 510 620
Tx; K Exhaust Inlet Temperature 1040 1090
Px; bar Air Inlet Pressure 14 10
P, bar Exhaust Inlet Pressure 1.02 1.02
V' – Ratio of Core Volume on Air Side to Core Volume on Exhaust Side 1/3 1/2
t µm Slat Thickness 50.8 25.4
s gm Slat Spacing 508 254
R, m Inner Radius of Core 2 0.5
Outputs
L mm Flow Length (or Core Thickness) 91.8 24.0
WR m Core Width 1.981 0.867
ws m Seal Width 0.643 0.161
V m3 Void Volume of Core Under I Seal 0.08946 2.763x10"3
MR kg Mass of Core 2,340 48.6
TROT s Rotation Period 14.7 1.7

1 Finite core-rotation speed reduces regenerator effectiveness

somewhat, so the size and weight of the Baleen Regenerator
must be increased somewhat to compensate.

4
Step 1: Calculate Fluid Properties
CC (4)
We calculate the necessary properties of the air and the kVR
exhaust from the inputs (which Table I lists) and from the
specified regenerator effectiveness. Effectiveness is defined as where
CC is the core compactness (m 2 );
£ _ (1) (hA) is the convective conductance associated with
Txi — TN. the core passages (W/K);

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where
T N0 is the outlet temperature on the air side (K);
T N; isthe inlet temperature on the air side (K); and
Tx; is the inlet temperature on the exhaust side (K)
We use the definition of effectiveness to calculate the
outlet temperature 2 on the air side:
k is the thermal conductivity of the gas (W/m-K); and
V R is the volume of the core (m 3 ).
A high convective conductance is required to achieve a high
effectiveness. Therefore, core compactness is a measure of the
amount of effectiveness potential that a core has per unit of
core volume.
Permeability is defined as

TN. = FT,0 + ( 1— s)T,,,; (2) .tLV

This equation shows that if a heat exchanger could achieve a
perfect effectiveness of c = 1, then the outlet temperature on the
air side would be exactly equal to the exhaust inlet temperature.
A perfect effectiveness of 1, however, is unachievable.
We use the first law of thermodynamics to calculate the
outlet temperature on the exhaust side. The outlet specific
enthalpy on the exhaust side is
(3)
hxo = hxi — mN )(h,,o — h.)
x
where
hx is the inlet specific enthalpy on the exhaust side
(J/kg);
h No is the outlet specific enthalpy on the air side (J/kg);
h N; is the inlet specific enthalpy on the air side (J/kg);
m N is the mass-flow rate on the air side (kg/s); and
x= (5)
(AP)coREAroT
where
K is the permeability (m 2 );
µ is the fluid's viscosity (Pa-s);
L is the core thickness or flow length (m);
V is the volumetric gas-flow rate (m 3/s);
(OP) is the pressure drop across the core (Pa); and
ATOT is the total core area normal to the flow (m 2 ).
For a given fluid and a given core thickness, a high
permeability is associated with a low core pressure drop.
In regenerator design, we allow very low permeabilities, but we
make the core pressure drops low by using thin cores (small
flow lengths, L).
For laminar flow through uniform passages, core
compactness and permeability are

m x is the mass-flow rate on the exhaust side (kg/s). 4pNu

CC = and (6)
We calculate the specific enthalpies from the temperatures H
(and vice versa) using the correlations of Chappell and
Cockshutt (1974).
K= C
D p ( 7)
r
Step 2: Calculate Core Performance
where
In order to calculate our Baleen Regenerator designs, we
need expressions for the performance of the core. The key p is the core porosity, void volume divided by
parameters that quantify the heat-transfer and pressure-drop total volume (-);
performances of regenerator cores are core compactness Nu is the Nusselt number, hD H/k (-);
(heat-transfer performance) and permeability (pressure-drop D H is the hydraulic diameter (m); and
performance). Core compactness is defined as C f is the friction coefficient (-).

2 All temperatures and pressures are total (or stagnation) properties.

5
The passages of the Baleen Regenerator are not uniform—the TABLE 2. PERFORMANCES OF ALTERNATIVE PASSAGE
slat spacing decreases linearly from the outer radius of the core GEOMETRIES, FROM KAYS AND LONDON
to the inner radius. However, simple calculations show that (1984) AND KAYS AND CRAWFORD (1980)
the effects are typically small. For our Baleen-Regenerator
designs, core compactness increases slightly (about 5%) and
permeability decreases slightly (about 5%).
The product of core compactness and permeability is often
Passage Geometry Nu Cr Nu/Cf

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used to quantify an overall heat-exchanger-core performance
that includes heat-transfer and pressure-drop performances:

(hA) 3.00 13.33 0.225

V or (8)
CC x K =
coRE
[ (^) JL J
I
TOT

z
2 ^Nu (9) I ❑ 3.61 14.2 0.254
CC x K =
r 1

Equation 8 tells us that the product of core compactness and

permeability is the product of the amount of convective
conductance per unit of core pressure drop and a term that F7 3.73 14.6 0.255
contains just fluid properties, the area normal to the flow, and 1.43
the flow rate. Therefore, the product of core compactness and
permeability is truly a good indicator of the overall
performance of a heat exchanger core.
Equation 9 offers more insight. Equation 9 tells us two 4.12 15.6 0.264
things: u
z
(1) The ratio of the Nusselt number to the friction
coefficient should be as large as possible to achieve
high core performance; and
(2) Core porosity should be as large as possible.
For laminar flow, the Nusselt number and friction coefficients Q 4.364 16 0.273

are dependent only on passage geometry. Table 2 lists Nusselt

numbers and friction coefficients that were taken from Kays
and London (1984) and Kays and Crawford (1980) for various
4.79 17.2 0.278
passage geometries. Clearly, the parallel-plate geometry has the
best performance. Therefore, the core of the Baleen 3
Regenerator offers the best possible heat transfer per unit of
pressure drop.
Equation 9 also tells us that the core porosity should be
high for high performance. The Baleen Regenerator's widely 5.33 18.3 0.291
spaced thin-foil slats produce a highly porous core, so the
Baleen Regenerator offers a large amount of heat transfer per 4
unit of core pressure drop.

6.49 20.6 0.315

Step 3: Calculate Regenerator Heat-Transfer Parameters
After all properties and the performances of the core have 8
been calculated, the next step is to calculate relevant
heat-transfer parameters so that a dimensionless core size,
NTU, can be calculated in Step 4. The dimensionless core size
is defined as 8.235 24 0.343
t— ono--►
NTU (Number of Transfer Units) _- C (10)
N [l/(hA) H +1/(hA) X ]

6
where
C N is the heat-capacity rate of the compressed-air
flow (W/K);
(hA) N is the convective conductance on the air side
(W/K); and
(hA) x is the convective conductance on the exhaust
side (W/K).
For regenerators, the dimensionless core size is a function of
seven other dimensionless heat-transfer parameters:
(1) c, effectiveness, which Equation I defines;
(2) C RAT , heat-capacity-rate ratio, the ratio of the
heat-capacity rate on the air side to that on the
exhaust side;
(3) CROT, a dimensionless core-rotation rate;
(4) X, a core-conduction parameter;
(5) As', solid-area ratio, the ratio of the solid area on the
air side to that on the exhaust side;
(6) SC, seal coverage, the fraction of the core face area
covered by seals; and
(7) (hA'), convective-conductance ratio, the ratio of the
convective conductance on the air side to that on the
exhaust side.
Beck and Wilson (1995) and Beck (1994) give a method
for calculating regenerator effectiveness from NTU and the
other six heat-transfer parameters. In regenerator design, we
specify effectiveness and determine NTU. Therefore, we use
an iterative approach: we specify trial NTU values, calculate
effectiveness using the method of Beck and Wilson (1994) and
Beck (1994), and modify our trial NTU values until we converge
on our specified effectiveness. The following paragraphs show
how we calculate the heat-transfer parameters listed above.
We calculate the heat-capacity-rate ratio from the
mass-flow rates and the specific heat capacities:
r NCPN (11)
m X c PX
where
in is the mass-flow rate on the indicated side (kg/s); and
c is specific heat capacity calculated at the average
P
temperature on the indicated side (J/kg-K).
The effectiveness of a regenerator approaches that of a
counter-flow recuperator with similar dimensions if the core
rotates infinitely fast. For slower core-rotation rates, the
temperature profile in the core varies significantly during the
flow exposures, and the effectiveness of the regenerator is less.
A dimensionless core-rotation rate is defined as
C ROT ° m R C ,
R (
m N C PN
where
m is the mass-flow rate of the core material (kg/s); and
R
CR is the average specific heat capacity of the core
material (J/kg-K).
If the dimensionless core-rotation rate is equal to about 5, then
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the effectiveness of the regenerator is very close (to within less
than 1% typically) to the effectiveness of the counter-flow
recuperator. A high core-rotation rate, however, produces a
high carry-over leakage. Typically, designers select core-
rotation rates in the range 2 < CROT < 5. We have designed for
rotation rates at the lower end of this range for the Baleen
Regenerator, because the core is so porous that carry-over
leakage tends to be high. We use Harper's (1957) results to
calculate the dimensionless core-rotation rate from the
specified acceptable carry-over leakage:
m 1— PVOL 1 ( )
CROT— 13
mC PVOL IPN CPN 1 — PXi /PNi
where
m XLC is the carry-over leakage (kg/s);
m, is the compressor mass-flow rate (kg/s);
PVOL is the average core porosity over the entire core
volume (-);
P R is the density of the core material (kg/m 3 ); and
pN is the average density of the compressed air
(kg/m 3 ).
Core heat conduction in the direction of fluid flow reduces
the effectiveness of a heat exchanger (see Bahnke and Howard,
1964, Beck and Wilson, 1995, and Beck, 1994). The effects of
conduction principally depend on three parameters: (1) the
conduction parameter, X; (2) the solid-area ratio, As'; and
(3) the seal coverage, SC. The conduction parameter is
defined as
kR(AsN + As,)
C N,L
(14)
where
k R is the thermal conductivity of the core material
(W/m-K);
As is the solid area available for heat conduction in
the core portion exposed to the indicated flow
(in');
C N is the heat-capacity rate of the air flow (W/K);
and
12) L is the core thickness or flow length (m).
In our sizing method, we calculate the conduction parameter Step 5: Calculate Reaenerator Dimensions
as follows: After the dimensionless size of the Baleen Regenerator's
core (NTU) has been calculated, we calculate some dimensions
kR(1 + V')( 1 - P) Lxmx of the Baleen Regenerator:
(15) (1) W R , the width of the core (m);
CN ( AP )CORE.X K PX
(2) mR , the mass of the core (kg);
where (3) TROT, the period of rotation of the core (s);

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(4) w, the width of a seal (m); and
is the core porosity at the mean core radius (-); and (5) V im , the void volume under one seal (m 3 ).
p x is the average density of the exhaust (kg/m 3 ). The last two dimensions are required to estimate the amount of
direct seal leakage that the Baleen Regenerator will have using
Harper's (1957) method. We calculate the dimensions as
The effects of core conduction in regenerators depend on
follows:
the solid-area ratio. The solid-area ratio is equal to the
core-volume ratio:
Vx(1+V')
WR —_ (19)
R (1— SC)rt(R' — R)
As' = V' (16)
where
The effects of core conduction in regenerators also depend on
the seal coverage (see Beck and Wilson, 1995, and Beck, V x is the core volume on the exhaust side (m 3 ); and
1994), which we specify. High-effectiveness regenerators rely R o is the outer core radius (m) (note that L = R 0-R).
on a steep temperature profile through the core. While the core
passes under the seals, this steep profile degrades toward the mR = PRNSLATSLtWR (20)
mean core temperature. This degradation reduces regenerator
effectiveness in direct relation to the width of the seals or the where
seal coverage.
NSLATS is the number of slats that comprise the core (-); and
The effects of the convective-conductance ratio on
t is the thickness of the slats (m).
regenerator effectiveness are typically small. The convective-
conductance ratio differs from the core-volume ratio by the
ratio of the fluid conductivities: TROT mRCR (21)
C ROT C N

(hA)' = V' (17)

xJ
wS = (22)
J SC7t(R + R )
o ;

Step 4: Calculate Dimensionless Core Size (NTU)

We calculate the dimensionless size of the Baleen Vrrs = PVOL(2)SCWR [7t(Ro — R2)— Nsursl t] (23)
Regenerator's core (NTU) using an iterative procedure because
the core-performance parameters, core compactness and K, as
well as the dimensionless core-rotation rate, CROT, depend on
the core thickness, L, and the core thickness depends on the 5 CONCLUSIONS
core size. We use an iterative procedure with seven principal This paper has described the compact and lightweight
steps: Baleen Regenerator. Also, this paper has presented a method
(1) Initialize L; for designing the Baleen Regenerator and other regenerators
(2) Calculate core compactness; directly from input specifications. The heat-transfer and
(3) Calculate K; pressure-drop performance parameters for the Baleen
(4) Calculate CROT; Regenerator's core have been derived.
(5) Calculate NTU;
(6) Calculate L; and
(7) Go to Step 2 until convergence. 6 ACKNOWLEDGEMENTS
In our iterative procedure, we calculate the core thickness as The Baleen Regenerator is being developed under a
follows: research project for the United States Air Force, Wright
Laboratory, Air Base Systems Branch, Tyndall AFB, Florida.
L= KPXyX(AP)rnRax (18) The author acknowledges the support and interest of the Project
ltxmx Officer, Mr. Reza Salavani.

8
7 REFERENCES
Bewley, A.D., 1990, "Cycle Analysis or Helicopter Gas
Turbine Engines," Trans. ASME Jr(. Of Eng. For Gas
Turbines and Power, Vi 12, pp. 199-205.
Bahnke, G.D. and Howard, C.P., 1964, "The Effect of
Longitudinal Heat Conduction on Periodic-Flow Heat
Exchanger Performance, "Trans. ASME, Jrl. of Eng. for

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Power, V86.
Beck, D.S., 1994, "The Effect of Seal Width on Regenerator
Effectiveness," Trans. ASME, Jrl. of Eng. for Gas
Turbines and Power, Vi 16(3).
Beck, D.G. and Wilson, D.G., 1995, Gas-Turbine Regenerators,
to be published by Chapman and Hall, New York, NY.
Chappell, M.S. and Cockshutt, E.P., 1974, "Gas Turbine Cycle
Calculations: Thermodynamic Data Tables for Air and
Combustion Products for Three Systems of Units," NRC,
Aeronautical Report LR-579, National Research Council
of Canada.
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