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SHOTEAM: Superalloy Heat exchangers Optimized for Temperature Extremes and Additive Manufacturability

University of California, Los Angeles (UCLA)
Program: 
ARPA-E Award: 
$2,520,000
Location: 
Los Angeles, CA
Project Term: 
09/30/2019 to 09/29/2022
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: 

UCLA will develop an extreme-condition heat exchanger technology targeted to ultra-high efficiency hybrid aviation power cycles. The heat exchanger will operate at 50 kW (thermal) at supercritical CO2 pressures of 80 and 250 bar (1160 and 3626 psi) in hot and cold streams and at a hot-stream inlet temperature of 800°C (1472°F). A metallic superalloy capable of withstanding high temperature and pressure will be used to fabricate a shell-and-tube-based design supplemented with 3D-printed tube augmentations. The optimized design will enhance overall heat transfer while maintaining a small overall form factor and low weight. The heat exchanger could dramatically improve efficiency and power density for new hybrid aviation power cycles.

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: 
Prof. Timothy Fisher
Release Date: 
8/9/2018