Hydrogen Cooler Thermal Design

Hydrogen coolers are used to reduce the temperature of hydrogen gas,
which is often used as a cooling medium in large electrical generators due to its:
• High thermal conductivity
• Low density (which reduces windage losses)
• Non-corrosive and inert nature (under normal conditions)
Hydrogen absorbs heat from generator components (like stator windings and the rotor) and
transfers this heat to the cooler, where it is removed—usually by a water or air-cooled heat exchanger.
Water-cooled Hydrogen Coolers are most common with water as cooling medium.
Air-cooled Hydrogen Coolers with air as the secondary cooling medium are less common.
They are less efficient than water-cooled, but simpler in design.
Most suitable materials forh hydrogen and heat applications:
a. Tube Materials:
• Copper-nickel alloys: Good thermal conductivity and corrosion resistance.
• Stainless steel: Common for high-strength applications, especially in water circuits.
b. Shell/Casing:
• Typically carbon steel or stainless steel, depending on temperature and pressure requirements.

Cooler arrangement:

Hydrogen side input:

Pressure, psia:

Flow rate:

Allowable pressure drop, in. water:

Fouling factor, ft2-hr-F/BTU:

Entering temperature, F:

Leaving temperature, F:

Tube side input:

Stream:

Pressure, psig:

Allowable pressure drop, psi:

Fouling factor, ft2-hr-F/BTU:

Entering temperature, F:

Leaving temperature, F:

Geometry & construction

Tube OD, in.

Tube material

Tube wall thickness, in.

Fin material

Assumed tube bundle length, ft: *

Assumed tube bundle width, ft: *

Tube inlet connection size, in.

Tube outlet connection size, in.

Fin height, in.

Gap between finned tubes in row, in.

Number of rows

Number of passes

Fin thickness, in.

Fin style

Fins per inch.

Fill properties @ avarage temperature °F for OTHER than WATER tube side fluids and choose type of fluid :

Viscosity, cp:

Density, Lb/ft3:

Specific heat, Btu/lbm °F:

Thermal conductivity, Btu/(hr ft °F):

Select type of fluid:

*-If boxes are empty, program will calculate length and width based on default face velocity.

Check input.