Rapid Prototyping of Low-Cost Compact Ceramic Industrial Heat Exchanger Elements

In industrial processes based on fossil fuels, energy is lost in the form of high quality exhaust gas, with temperatures ranging from as low 600oF (315oC) to as high as 3000oF (1648oC). Although metallic-alloy heat exchanger technology currently exists to capture a portion of this energy, the alloy is limited by its ability to be used at high temperatures and to be manufactured in cost effective designs. This project will develop a rapid prototyping (three-dimensional printing) method for producing low-cost, high-temperature, near-net-shape, siliconized silicon carbide, compact heat exchangers with enhanced heat transfer geometries. The method will be applied to the development of low-cost, industrial heat exchangers that operate up to 2450oF in harsh industrial heating environments. Commercial Applications and other Benefits as described by the awardee: The technology should directly impact the ability to recover heat in industries such as primary steel, heat treating, forging, metal casting, aluminum, pulp and paper, glass, petroleum, chemical, and food products. Extension to the commercial and utility boiler market, solid oxide fuel cells, turbines, and even body armor should b a logical follow-on.