Micro-Structured Heat Exchangers & Reactors for ISRU
A. McCandless1, S. Motakef2, D. Guidry1, and M. Overholt2
1International Mezzo Technologies, Inc.2Cape Simulations, Inc.
November 2, 2004
New Enabling New Enabling TechnologyTechnology
High performance micro-High performance micro-machined thermo-chemical machined thermo-chemical devices for energy conversion devices for energy conversion and In-Situ Resource Utilization:and In-Situ Resource Utilization:– Heat ExchangersHeat Exchangers– ReactorsReactors
Core Technology
Micro-manufacturing – devices with micro-scale
features (10’s of microns) over macro-scale dimensions of (1-100 cm)
Micro-Channel Micro-Channel Thermo-Chemical DevicesThermo-Chemical Devices
Applications for Moon & Mars Applications for Moon & Mars Missions:Missions:– Propellant productionPropellant production– Fuel cell reagant productionFuel cell reagant production– Human habitat power & life support Human habitat power & life support
systemssystems
High Temp. ProcessesHigh Temp. ProcessesCandidate Process Output Operating
Temp.Equipment Needed
Hydrogen Reduction of Ilmenite
Fe, O2 900 oC 25C
High-Temp. Heat Exchanger Condenser
Carbo-thermal Methane Reduction
Fe, Si, O2 1625 oC;250 oC 25 oC
High-Temp. Heat ExchangerLow-Temp. Heat Exchanger
Vapor Pyrolysis O2, Fe, Al, Ca 2000 oC High-Temp. Heat Exchanger
Zirconia Solid CO2
Oxide Electrolysis
O2 900-1000 oC Catalytic Reactor High-Temp. Heat Exchanger
Sabatier Catalytic Reaction
H2O, CH4 200-300 oC Catalytic ReactorLow-Temp. Heat Exchanger
Reverse Water Gas Shift Reaction
H2O 400-650 oC. Catalytic ReactorMid-Temp. Heat Exchanger
Methane Reforming H2O, CH4 250 oC. Catalytic ReactorLow-Temp. Heat Exchanger
Hydrothermal Reduction of Mars soil
H2O, Fe 1000 oC High-Temp. Heat Exchanger
Lunar
MarsSource:
R.S. Baird
Micro-Channel Micro-Channel Thermo-Chemical DevicesThermo-Chemical Devices
Heat Exchangers:Heat Exchangers:Micro-structured surfaces Micro-structured surfaces
lower diffusive thermal lower diffusive thermal resistances resistances
Higher performance Higher performance per per weight & volumeweight & volume
Micro-Channel Micro-Channel Thermo-Chemical DevicesThermo-Chemical Devices
ReactorsReactors– Reduced resistance to mass transferReduced resistance to mass transfer– Intimate thermal exchange between Intimate thermal exchange between
catalytic reactor and heat catalytic reactor and heat exchangerexchanger
– Intimate thermal coupling of endo- Intimate thermal coupling of endo- and exo-thermic reactionsand exo-thermic reactions
– Accurate control of reaction Accurate control of reaction temperaturetemperature
– Non-Equilibrium chemical productsNon-Equilibrium chemical products
Micro-channels in Cross Micro-channels in Cross Flow Heat ExchangersFlow Heat Exchangers
In-plane cross section
Cross Flow Gas-Liquid Heat Exchangers
Liquid Inlet
Liquid Outlet Heat Exchange Panel
Gas Flow
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
0 2 4 6 8 10 12
SCFM/in2
W/K
/in
2
Lytron M10-080 Lytron 4320
Lytron 4105 Lytron M05-050
Lytron M14-120 Lytron M14-240
Lytron AS04-05 Lytron AS06-08
Lytron AS08-10 Lytron 4120
Lytron 4210 Lytron 4220
Lytron 4310 Lytron 4110
MEZZO 2 Panels MEZZO 1 Panel
Comparison with Existing Technology
Heat Transfer Per Unit of Frontal Area
0
2
4
6
8
10
12
14
0 2 4 6 8 10 12
SCFM/in2
W/K
/in
3
Lytron 4110 Lytron 4320
Lytron 4105 Lytron M05-050
Lytron M10-080 Lytron M14-120
Lytron M14-240 Lytron AS04-05
Lytron AS06-08 Lytron AS08-10
Lytron 4120 Lytron 4210
Lytron 4220 Lytron 4310
MEZZO 1 Panel MEZZO 2 Panels
Heat Transfer Per Heat Transfer Per Unit VolumeUnit Volume
Comparison with Comparison with Existing TechnologyExisting Technology
Comparison with Comparison with Existing TechnologyExisting Technology
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
0 2 4 6 8 10 12
SCFM/in2
inch
H20
Lytron 4110 Lytron 4320
Lytron 4105 Lytron M05-050
Lytron M10-080 Lytron M14-120
Lytron M14-240 Lytron AS04-05
Lytron AS06-08 Lytron AS08-10
Lytron 4120 Lytron 4210
Lytron 4220 Lytron 4310
MEZZO 1 Panel MEZZO 2 Panels
Pressure Per Pressure Per Unit Frontal AreaUnit Frontal Area
Comparison with Existing Technology
Compact PlateFin Heat Exchanger
Comparison with Existing Technology
Comparison with a truck radiator: the same heat transfer per Comparison with a truck radiator: the same heat transfer per frontal area, but much higher performance per volume & mass.frontal area, but much higher performance per volume & mass.
Example of Packaged HXExample of Packaged HX
Corrugated Heat Corrugated Heat Exchangers Yield Ultra Low Exchangers Yield Ultra Low Frontal AreaFrontal Area
Heat exchanger can be inside the duct!
Lithography
Metalization
Post Machining
Electroplating
Molding
LIGA Process
Advantages of LIGA
Tall/deep structures up to 3 mm/high aspect ratios: up to 100
Vertical sidewalls: 1um/1000 um slope Smooth sidewalls: less than 30 nm
variations Lateral dimensional control: better than
1 um Materials: Metal, Ceramic, Polymer Low per-unit manufacturing cost
Additional Types of Heat Additional Types of Heat ExchangersExchangers
Gas – GasGas – Gas Liquid – LiquidLiquid – Liquid Vapor – GasVapor – Gas Vapor – LiquidVapor – Liquid
Micro Jet Cooling Array Micro Jet Cooling Array
Systems for removal of very high heat fluxes
Micro Jet Cooling ArrayMicro Jet Cooling Array
Single phase impingement cooling >100 impinging microjets/cm2
Very high heat transfer coefficients Easily removes 1kW/cm2 of heat
4-kWatt Cold Plate4-kWatt Cold Plate
Ceramic Micro-channel Ceramic Micro-channel DevicesDevices
Applications:Applications:– High Temperature Heat High Temperature Heat
ExchangersExchangers– High Temperature ReactorsHigh Temperature Reactors– RecuperatorsRecuperators
Ceramic Micro-channel Ceramic Micro-channel DevicesDevices
AdvantagesAdvantages– Can go up to very high temperaturesCan go up to very high temperatures– Hospitable to a wide range of Hospitable to a wide range of
catalystscatalysts ChallengesChallenges
– Creation of high aspect ratio Creation of high aspect ratio structuresstructures
– Ceramic-Ceramic bondingCeramic-Ceramic bonding
Ceramic Micro-channel Ceramic Micro-channel DevicesDevices
500 500 m x 1.5 mm m x 1.5 mm structures in sintered SiNstructures in sintered SiN
Ceramic Micro-channel Ceramic Micro-channel DevicesDevices
Bonding of Ceramic PlatesBonding of Ceramic Plates– Strong ceramic-ceramic bonds Strong ceramic-ceramic bonds
createdcreated (Please see me for samples)(Please see me for samples)
– Mechanical tests to be conducted Mechanical tests to be conducted shortlyshortly
Ceramic Micro-channel Ceramic Micro-channel DevicesDevices
Building Block:Building Block:
Micro-machined ceramic panelMicro-machined ceramic panel
Ceramic Micro-channel Ceramic Micro-channel DevicesDevices
Counterflow fluids in alternating layers very effectively coupled via fins
Individual ceramic plates, aligned, pressed together, then sintered
Fins:Length 1.5-2.5 mmWidth at base: 300 mWidth at tip: 200 mGap Between Fins 300-400 m
Ceramic Micro-channel Ceramic Micro-channel DevicesDevices
Counter FlowCounter Flow
Examples of Ceramic Heat Exchangers & ReactorsExamples of Ceramic Heat Exchangers & Reactors
Cross FlowCross Flow DogboneDogbone
Ceramic Micro-channel Ceramic Micro-channel DevicesDevices
Gas Turbine Recuperator for Gas Turbine Recuperator for UMAVUMAV– 81% effectiveness81% effectiveness– 30 kW capacity30 kW capacity– Weight = 2lbsWeight = 2lbs– Volume = 6” x 2” x 6”Volume = 6” x 2” x 6”
Additional Manufacturing Technologies
Surface Micromachining Tradition and Micro Electro Discharge
Machining (EDM) Sinker Wire
UV Lithography Etching Laser Drilling, Cutting, and Welding
Collaborators
Heat Exchangers/ Chemical Reactors
Honeywell, MDA, General Dyanmics, Praxair, EADS, Lockheed Martin, Intel, & M-DOT
MicroJet Cooling Lockheed Martin ONR, MDA, Army, & NRL
Integrated HX & Mechanical Seals
NAVAIR, G.E., Rolls Royce, ASI, & Cooligy
Regenerator MDA, Air Force, Ball, L.M., Raytheon, & N.G.
CollaborationsCollaborations
We are looking for opportunities We are looking for opportunities to collaborate on design, to collaborate on design, modeling, fabrication, and modeling, fabrication, and testing of heat exchangers and testing of heat exchangers and reactors.reactors.
Micro-Channel Micro-Channel Thermo-Chemical Thermo-Chemical
DevicesDevices
Thank You!Thank You!