A regenerative heat exchanger, or more commonly a regenerator, is a type of heat exchanger where the flow through the heat exchanger is cyclical and periodically changes direction. It is similar to a countercurrent heat exchanger. However, a regenerator mixes the two fluid flows while a countercurrent exchanger maintains them separated. The temperature profile remains at a nearly constant temperature, and this includes the fluid entering and exiting each end.
In regenerative heat exchangers, the fluid on either side of the heat exchanger is nearly always the same fluid. The fluid is cycled through the heat exchanger, often reaching high temperatures. The fluid may go through an external processing step, and then it is flowed back through the heat exchanger in the opposite direction for further processing. Usually the application will use this process cyclically or repetitively. Thus, in regenerative heat exchangers, a fluid incoming to a process is heated using the energy contained in the fluid exiting this process.
The regenerative heat exchanger gives a considerable net savings in energy, since most of the heat energy is reclaimed nearly in a thermodynamically reversible way. This type of heat exchanger can have a thermal efficiency of over 90%, transferring almost all the relative heat energy from one flow direction to the other. Only a small amount of extra heat energy needs to be added at the hot end, and dissipated at the cold end, even to maintain very high or very low temperatures.
In a fixed matrix regenerator, a single fluid stream has cyclical, reversible flow; it is said to flow "counter-current". This regenerator may be part of a valveless system, such as a Stirling engine. In another configuration, the fluid is ducted through valves to different matrices in alternate operating periods Ph and Pc resulting in outlet temperatures that vary with time.
Another type of regenerator is called a micro scale Regenerative Heat Exchanger. It has a multilayer grating structure in which each layer is offset from the adjacent layer by half a cell which has an opening along both axes perpendicular to the flow axis. Each layer is a composite structure of two sublayers, one of a high thermal conductivity material and another of a low thermal conductivity material. When a hot fluid flows through the cell, heat from the fluid is transferred to the cell wells, and stored there. When the fluid flow reverses direction, heat is transferred from the cell walls back to the fluid. A third type of regenerator is called a "Rothemuhle" regenerator. This type has a fixed matrix in a disk shape, and streams of fluid are ducted through rotating hoods. The Rothemuhle regenerator is used as an air preheater in some power generating plants. The thermal design of this regenerator is the same as of other types of regenerators.
The design of inlet and outlet headers used to distribute hot and cold fluids in the matrix is much simpler in counter flow regenerators than recuperators. The reason behind this is that both streams flow in different sections for a rotary regenerator and one fluid enters and leaves one matrix at a time in a fixed-matrix regenerator. Furthermore flow sectors for hot and cold fluids in rotary regenerators can be designed to optimize pressure drop in the fluids. The matrix surfaces of regenerators also have self-cleaning characteristics, reducing fluid-side fouling and corrosion. Finally properties such as small surface density and counter-flow arrangement of regenerators make it ideal for gas-gas heat exchange applications requiring effectiveness exceeding 85%. The heat transfer coefficient is much lower for gases than for liquids, thus the enormous surface area in a regenerator greatly increases heat transfer.
Researchers Submit Patent Application, "Device for Exhaust Gas Heat Utilization, Exhaust Gas Module Having Such a Device, and Method of Manufacturing the Device", for Approval
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