High-Temperature Compact Heat Exchangers for Harsh Environments

The Department of Energy is seeking innovative solutions for high-temperature compact heat exchangers (CHXs) that can operate in harsh environments. The current limitations of existing CHXs made from nickel-based alloys include temperature constraints, corrosion issues, design limitations, and energy-intensive manufacturing. The proposed solution introduces high-performance CHXs using Mo- and W-based refractory alloys combined with advanced manufacturing techniques, including 3D channel fabrication and efficient sintering processes. The key advantages of this approach include enhanced durability, energy efficiency, customizable designs, embedded monitoring, and cost savings. The market applications for this technology include power generation, chemical processing, metallurgy, and industrial safety. • High-temperature compact heat exchangers for harsh environments • Refractory metal designs with embedded sensors for enhanced performance and reliability • Advanced manufacturing techniques, including 3D channel fabrication and efficient sintering processes • Customizable designs for improved heat transfer and flow performance • Embedded sensors for real-time monitoring of temperature and strain • Cost savings through reduced manufacturing energy use and scalable methods