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A 2-5 MW Supercritical CO2 micro tube recuperator: manufacturing, testing, and laser weld qualification

International Mezzo Technologies
Program: 
ARPA-E Award: 
$1,419,417
Location: 
Baton Rouge, LA
Project Term: 
09/18/2019 to 03/17/2022
Project Status: 
ACTIVE
Technical Categories: 
Critical Need: 
Heat exchangers are critical to efficient thermal energy exchange in a variety of applications, including electricity generation, transportation, petrochemical plants, waste heat recovery, and more. Heat exchangers designed to handle very high pressures and high temperatures simultaneously are more efficient and compact. Their design also requires finer heat transfer surface and fin features at the limits of existing manufacturing capabilities with high temperature materials. Durable, reliable, and cost-effective higher temperature and pressure heat exchangers that exceed current operating conditions could reduce fuel consumption, system footprint, and capital cost while boosting the performance of a variety of power generation and industrial processes.
Project Innovation + Advantages: 
International Mezzo Technologies will design, manufacture, and test a compact, nickel-based superalloy supercritical carbon dioxide (sCO2) recuperator (a type of heat exchanger). The recuperator will incorporate laser-welded micro tubes and function at 800°C (1,472°F) and 275 bar (3,989 psi). Currently, the cost of recuperators for power systems operating in these conditions is prohibitive. Laser welding micro tubes offers a low-cost approach to fabricating heat exchangers, which could increase the economic competitiveness of sCO2 power cycles. Mezzo's program could provide a pathway to manufacture relatively inexpensive heat exchangers for high temperature-high pressure applications.
Potential Impact: 
HITEMMP projects will enable a revolutionary new class of heat exchangers and innovative approaches to advanced manufacturing with applications for a wide range of commercial and industrial energy producers and consumers.
Security: 
High performance, efficient heat exchangers would increase industrial productivity, supporting domestic industries. The developed manufacturing techniques for high temperature materials could strengthen U.S. leadership in advanced manufacturing.
Environment: 
More efficient electricity generation and industrial processes could significantly reduce emissions by enabling more efficient operations.
Economy: 
HITEMMP technologies could enable more cost-effective, efficient, and compact modular power generation systems for multiple applications.
Contacts
ARPA-E Program Director: 
Dr. Michael Ohadi
Project Contact: 
Dr. Kevin Kelly
Release Date: 
8/9/2018