Low Cost Microchannel Heat Exchangers

Microchannel heat exchangers can greatly reduce heat exchanger size and weight, but are too expensive for most applications, because of high fabrication costs. This project will develop an innovative microchannel heat exchanger that uses low-cost materials, along with a low precision fabrication technique, to reduce heat exchanger cost by 58%. Moreover, the volume and weight of the heat exchanger will be reduced by 98% and 72%, respectively, relative to conventional plate and fin heat exchangers. In Phase I, the innovative microchannel heat exchanger was designed, and the fabrication approach was evaluated. A heat exchanger was built and tested to demonstrate manufacturability and performance. Lastly, the design and performance projections were updated, and costs were estimated, in order to demonstrate technical and economic feasibility. Phase II will involve the coordination of machining, manufacturing, and bonding processes to develop and demonstrate prototype microchannel heat exchangers for several applications of interest. Commercial Applications and Other Benefits as described by the awardee: The microchannel heat exchangers should find use in energy, power, refining, chemical processing, hydrocarbon gas, and liquefied natural gas applications. If the concept was adapted to high volume applications, cost savings could be over $100 million/year.