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Heat-Exchanger Intensification through Powder Processing and Enhanced Design (HIPPED)

Michigan State University (MSU)
Program: 
ARPA-E Award: 
$2,250,000
Location: 
East Lansing, MI
Project Term: 
09/27/2019 to 09/26/2022
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: 

Michigan State University's proposed technology is a highly scalable heat exchanger suited for high-efficiency power generation systems that use supercritical CO2 as a working fluid and operate at high temperature and high pressure. It features a plate-type heat exchanger that enables lower cost powder-based manufacturing. The approach includes powder compaction and sintering (powder metallurgy) integrated with laser-directed energy deposition additive manufacturing. Each plate is covered with packed, precisely designed and formed three-dimensional features that promote mixing, intensify heat transfer, and provide stability to prevent large plate deformation under high pressure. The super-alloys developed provide strength at the highest operating temperatures (1100°C) and significant corrosion resistance. The proposed concept extends the range for indirect heat exchange to extreme conditions where state-of-the-art heat exchangers cannot operate. In addition, new ferrous- and nickel-based alloys developed are suitable for other high temperature 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. Andre Benard
Partners
University of Michigan
Release Date: 
8/9/2018