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High Temperature, High Pressure, and High Performance Compact Heat Exchanger

Thar Energy
Program: 
ARPA-E Award: 
$3,150,000
Location: 
Pittsburgh, PA
Project Term: 
09/16/2019 to 09/15/2022
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 processing, and waste heat recovery. Heat exchangers designed to handle ultra high pressures and high temperatures simultaneously would help to facilitate more efficient and cost effective thermochemical processes. However, the successful design of such devices is expected to require heat transfer surface and fin features that are too fine for current high temperature material manufacturing processes. 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: 
Thar Energy will develop a next-generation metallic compact recuperator, a type of heat exchanger, capable of stable and cost effective operation at 800°C (1562°F) and above 80 bar (1160 psi). A metallic superalloy capable of withstanding high temperature and pressure will be employed to fabricate the heat exchanger using a novel stacked sheet manufacturing technique. The cost-effective heat exchanger design could enable design enhancement with improved structural integrity and thermal performances for high-efficiency, modular, and cost-competitive recuperated supercritical carbon dioxide (sCO2) Brayton power cycle systems. Thar Energy will also develop and test an efficient, cost-effective, and sustainable power generation system. The new system will use its developed recuperator and novel high temperature components, such as a high-temperature primary heat exchanger and high-efficiency reciprocating expander capable of operations above 800°C and 300 bar.
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: 
Mr. Marc Portnoff
Release Date: 
8/9/2018