Ultra Performance Heat Exchanger Enabled by Additive Technology (UPHEAT)

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Program:
HITEMMP
Award:
$3,498,493
Location:
Fairfield, Connecticut
Status:
ACTIVE
Project Term:
07/22/2019 - 10/31/2023
Website:

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:

The GE-led team will develop a metallic-based, ultra-performance heat exchanger enabled by additive manufacturing technology and capable of operation at 900°C (1652°F) and 250 bar (3626 psi). The team will optimize heat transfer versus thermomechanical load using new micro-trifurcating core structures and manifold designs. The team will leverage a novel, high-temperature capable, crack-resistant nickel superalloy, designed specifically for additive manufacturing. When completed, the heat exchanger could enable increased thermal efficiency of indirect heated power cycles such as supercritical carbon dioxide (sCO2) Brayton power generation, reducing energy consumption and emissions.

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.

Contact

ARPA-E Program Director:
Dr. Philseok Kim
Project Contact:
Dr. Lana Osusky
Press and General Inquiries Email:
ARPA-E-Comms@hq.doe.gov
Project Contact Email:
Lana.Osusky@ge.com

Partners

Oak Ridge National Laboratory

Related Projects

• Carnegie Mellon University (CMU) - High Energy Density Modular Heat Exchangers through Design, Materials Processing, and Manufacturing Innovations
• CompRex - Compact Heat Exchanger for High Temperature High Pressure Applications Using Advanced Cermet
• General Electric (GE) Global Research - Ultra Performance Heat Exchanger Enabled by Additive Technology (UPHEAT)
• International Mezzo Technologies - A 2-5 MW Supercritical CO2 Micro Tube Recuperator: Manufacturing, Testing, and Laser Weld Qualification
• Massachusetts Institute of Technology (MIT) - Multiscale Porous High-Temperature Heat Exchanger Using Ceramic Co-Extrusion
• Michigan State University (MSU) - Heat-Exchanger Intensification through Powder Processing and Enhanced Design (HIPPED)
• Michigan Technological University (MTU) - High-density SSiC 3D-printed Lattices for Compact HTHP Aero-engine Recuperators
• Thar Energy - Recuperated Supercritical Carbon Dioxide Brayton Power Cycle System
• The Boeing Company - Highly Compact Metallic Heat Exchangers for Extreme Environments
• United Technologies Research Center (UTRC) - Low-Cost Glass Ceramic-Matrix Composite Heat Exchanger
• United Technologies Research Center (UTRC) - Additive, Topology-Optimized Ultra-Compact Heat Exchanger
• University of California, Los Angeles (UCLA) - SHOTEAM: Superalloy Heat exchangers Optimized for Temperature Extremes and Additive Manufacturability
• University of Maryland (UMD) - Additively Manufactured High Efficiency and Low-Cost sCO2 Heat Exchangers
• University of Missouri - UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers
• Vacuum Process Engineering (VPE) - Compact Diffusion Bonded Printed-Circuit Heat Exchanger Development Using Nickel Superalloys for Highly Power Dense and Efficient Modular Energy Production Systems

Release Date:
08/09/2018