High Temperature Heat Exchange Design and Fabrication for Systems with Large Pressure Differentials Email Page
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Performer:  Thar Energy, LLC Location:  Pittsburgh, Pennsylvania
Project Duration:  10/01/2014 – 12/31/2016 Award Number:  FE0024012
Technology Area:  Advanced Combustion Systems Total Award Value:  $625,000
Key Technology:  Enabling Technologies/Innovative Concepts DOE Share:  $500,000
Performer Share:  $125,000

High pressure CO<sub>2</sub> test stand at Thar Energy. Pumps<br/>are positioned to the left of separator vessels (used,<br/>for example, to knock out water) and auxiliary heat exchangers.
High pressure CO2 test stand at Thar Energy. Pumps
are positioned to the left of separator vessels (used,
for example, to knock out water) and auxiliary heat exchangers.

Project Description

Thar Energy, LLC and Southwest Research Institute propose the design of a compact heat exchanger using microchannel technology for operation at high temperature, up to 700 degrees Celsius, and high pressure differentials, approximately 2,500 psi between streams. This heat exchanger is intended for use in high-efficiency electrical generation systems such as supercritical carbon dioxide (CO2) power cycles. This project will consist of preliminary and detailed design and prototype fabrication and testing. Preliminary design efforts will include a technology gap study, heat exchanger tube material selection, analyses of manufacturing and fabrication techniques, and heat exchanger tube geometry design. Detailed design will consist of computational fluid dynamics (CFD), heat transfer, and structural analysis of the proposed design to examine the flow characteristics and thermal performance. Fabrication will demonstrate compatibility of the selected material and manufacturing technique. Prototype testing will consist of hydrostatic and pressurized flow testing at representative pressure differentials.

Project Benefits

The manufacturing technology that is expected from Thar Energy’s investigation will bring heat exchanger costs within a range that allows CO2 power cycles to reach acceptable levelized cost-of-electricity levels. The microchannel technology being developed here is also applicable to energy storage cells for phase-change materials, waste heat recovery, and even as nano-reactors for precise temperature-controlled reactions. Considerable amounts of waste heat energy remain unrecovered as a consequence of industrial manufacturing. Examples of such applications are furnace exhausts, cement kilns, incinerators, and single cycle gas turbine exhausts. Whether the heat is recovered into CO2, air, or steam, this microchannel technology will be applicable. It uses less material, saving on costs and reducing dependence on imports.

Presentations, Papers, and Publications

Contact Information

Federal Project Manager Seth Lawson: seth.lawson@netl.doe.gov
Technology Manager John Rockey: john.rockey@netl.doe.gov
Principal Investigator Lalit Chordia: lalit.chordia@tharenergyllc.com