High-temperature and high-pressure heat exchanger

Abstract

A high gravimetric and volumetric power density heat exchanger is provided for high-temperature and high-pressure applications with counter-flowing hot and cold agents that enter via respective inlet headers, transit parallel and adjacent flow passages, and exit via respective outlet headers. One or more headers for conveying one of the substances may be situated within the flow of the other substance. Structures within the flow passages promote the transfer of heat while limiting pressure drop on one or both sides. The structures may include microscale pins, an array of pins (with specified aspect ratios and spacing), a lattice of interconnected pins, parallel ridges, and/or other features. Through an additive manufacturing process, the headers are monolithically integrated into the heat exchanger instead of being separately constructed and attached.

What is claimed is: 
     
         1 . A heat exchanger device, comprising:
 a first pathway for conveying a first substance, the first pathway comprising:
 a first plurality of plates, wherein each plate encloses a first flow passage that includes a plurality of first structures; 
 a first inlet header configured to receive the first substance and direct the first substance through the first flow passages in the first plurality of plates; and 
 a first outlet header configured to receive the first substance from the first flow passages and expel the first substance from the device; and 
   a second pathway for conveying a second substance, the second pathway comprising:
 a plurality of second flow passages between adjacent plates in the first plurality of plates, wherein each second flow passage includes a plurality of second structures; 
 a second inlet header configured to receive the second substance and direct the second substance through the second flow passages; and 
 a second outlet header configured to receive the second substance from the second flow passages and expel the second substance from the device. 
   
     
     
         2 . The device of  claim 1 , wherein the first flow passages convey the first substance and the second flow passages convey the second substance in substantially opposite directions. 
     
     
         3 . The device of  claim 1 , wherein the first substance has a relatively high pressure and a relatively low temperature at the first inlet header, in comparison to the second substance at the second inlet header. 
     
     
         4 . The device of  claim 3 , wherein:
 the first inlet header receives the first substance at a pressure up to approximately 250 bar; and   the second inlet header receives the second substance at a temperature up to approximately 800° C.   
     
     
         5 . The device of  claim 1 , wherein the plurality of first structures comprises microscale pins. 
     
     
         6 . The device of  claim 5 , wherein the microscale pins have predetermined aspect ratios and spacing. 
     
     
         7 . The device of  claim 5 , wherein the microscale pins connect opposing walls of the plate. 
     
     
         8 . The device of  claim 1 , wherein the plurality of second structures comprises two or more parallel ridges. 
     
     
         9 . The device of  claim 1 , wherein the plurality of second structures comprises interlocking pins that form a lattice structure. 
     
     
         10 . The device of  claim 1 , wherein:
 the device further comprises a second plurality of plates enclosing the second flow passages; and   the first plurality of plates and the second plurality of plates are radially aligned between (a) the first inlet header and the second outlet header and (b) the second inlet header and the first outlet header.   
     
     
         11 . The device of  claim 10 , wherein:
 the plurality of second structures of one or more second flow passages converge in a direction of flow of the second substance through the second flow passages to control pressure loss of the second substance.   
     
     
         12 . The device of  claim 1 , wherein one or more of the first flow passages and the second flow passages have variable converging and/or diverging cross-sections that control loss of pressure of one or more of the first substance and the second substance. 
     
     
         13 . The device of  claim 1 , wherein the device is devoid of braze joints and weld joints. 
     
     
         14 . The device of  claim 1 , wherein the device is fabricated monolithically via a metal laser powder-based fusion additive manufacturing process. 
     
     
         15 . The device of  claim 1 , wherein the first substance comprises one or more of:
 supercritical carbon dioxide; and   molten salt.   
     
     
         16 . The device of  claim 1 , wherein the second substance comprises one or more of:
 molten salt;   fluidized metallic particles;   fluidized ceramic particles;   liquid sodium; and   a supercritical gas.   
     
     
         17 . A heat exchanger apparatus, comprising:
 a first inlet header for inletting a first fluidiform substance;   a second inlet header for inletting a second fluidiform substance;   a first outlet header for outputting the first fluidiform substance;   a second outlet header for outputting the second fluidiform substance;   a plurality of first passages through which the first substance flows between the first inlet header and the second inlet header; and   a plurality of second passages through which the second substance flows between the second inlet header and the second outlet header;   wherein the plurality of first passages and the plurality of second passages are parallel to and interleaved with each other.   
     
     
         18 . The apparatus of  claim 17 , further comprising:
 a plurality of first plates, wherein each first plate encloses one of the first passages.   
     
     
         19 . The apparatus of  claim 18 , wherein each first passage comprises microscale structures that connect opposing walls of the plate. 
     
     
         20 . The apparatus of  claim 19 , wherein the microscale structures include an array of pins having predetermined aspect ratios and spacing. 
     
     
         21 . The apparatus of  claim 18 , further comprising:
 a plurality of second plates, wherein each second plate encloses one of the second passages.   
     
     
         22 . The apparatus of  claim 21 , wherein each second passage comprises microscale structures that connect opposing walls of the plate. 
     
     
         23 . The apparatus of  claim 22 , wherein the microscale structures include a lattice of interconnecting pins. 
     
     
         24 . The apparatus of  claim 17 , wherein the first inlet header and/or the first outlet header are exposed to a flow of the second substance before and/or after the second substance flows through the plurality of second passages. 
     
     
         25 . The apparatus of  claim 17 , wherein the apparatus has a radial configuration in which:
 one of the inlet headers and one of the outlet headers form an inner arc;   the other of the inlet headers and the other of the outlet headers form an outer arc; and   the plurality of first passages and the plurality of second passages are radially aligned between the inner arc and the outer arc.