High-Temperature Compact Heat Exchangers for Harsh Environments
Closed Special Notice Posted
- Solicitation number
- BA-1545
- Agency
-
Department of Energy
- Responses due
- Set-aside
- No set-aside
Opportunity facts
- PSC
- 9660 Precious Metals Primary Forms
- Place of performance
- Idaho Falls, Idaho 83415, United States
- Points of contact
-
- Andrew Rankin td@inl.gov
Notice details come from SAM.gov. Updated .
About this opportunity
The Department of Energy (DOE) has issued a Special Notice focusing on innovative high-temperature compact heat exchangers (CHXs) for extreme industrial environments. The notice highlights a novel technology developed by Idaho National Laboratory (INL) that addresses critical limitations in existing heat exchanger designs. The technology utilizes molybdenum and tungsten-based refractory alloys to create heat exchangers capable of operating at significantly higher temperatures and in more corrosive conditions than traditional nickel-based alloys. This special notice aims to connect with potential industry partners interested in licensing and commercializing the advanced heat exchanger technology. The opportunity is categorized under Nonferrous Metal Rolling, Drawing, and Extruding and Precious Metals Primary Forms NAICS codes.
The primary objective of this special notice is to introduce a breakthrough technology that offers substantial improvements in heat exchanger performance and manufacturing efficiency for industries such as power generation, chemical processing, and metallurgy. The technology features 3D channel fabrication, electric field-assisted sintering, and embedded sensor capabilities that enable real-time structural health monitoring. Contractors and potential licensees can expect opportunities to develop heat exchangers with enhanced durability, operating at temperatures up to 1500C with superior corrosion resistance. The technology promises significant advantages, including a 90% reduction in manufacturing energy use, over 30% cost savings, and the ability to create customizable designs with integrated monitoring capabilities. Interested parties should note the opportunity is open until January 13, 2026, and the Technology Deployment department at INL is specifically seeking collaborations to bring this innovation to market, with a focus on licensing rather than direct procurement or service contracts.
Notice text
High-Temperature Compact Heat Exchangers for Harsh Environments
Refractory Metal Designs with Embedded Sensors for Enhanced Performance and Reliability
The Challenge
High-temperature compact heat exchangers (CHXs) are vital for industries like power generation, chemical processing, and metallurgy. However, existing solutions made from nickel-based alloys face critical limitations:
- Temperature Constraints: Mechanical strength deteriorates above 750°C.
- Corrosion Issues: May exhibit poor resistance to harsh environments, such as molten salts.
- Design Limitations: 2D channel configurations restrict heat transfer efficiency.
- Energy-Intensive Manufacturing: Current techniques, like diffusion bonding and brazing, are challenging, resource-heavy, and inefficient.
These barriers prevent CHXs from reaching the temperatures needed for peak efficiency and long-term durability in extreme conditions.
How It Works
This novel technology introduces high-performance CHXs using Mo- and W-based refractory alloys combined with advanced manufacturing techniques:
- Refractory Alloy Design: Mo- and W-based alloys are optimized for superior corrosion resistance (200%+ improvement over conventional materials) and mechanical strength at temperatures up to 1500°C.
- 3D Channel Fabrication: Customizable 3D flow channels are created using traditional additive manufacturing and digital light projection (DLP) printing, significantly improving heat transfer efficiency.
- Efficient Sintering Process: Electric Field Assisted Sintering (EFAS) compacts refractory alloys into robust structures, achieving a 70–90% reduction in energy consumption during manufacturing.
- Embedded Sensors: Aerosol Jet Printing (AJP) integrates multimodal sensors for real-time structural health monitoring (SHM), enabling advanced safety and reliability monitoring.
This integrated approach allows for the fabrication of durable, high-performance CHXs designed for extreme environments.
Key Advantages
- Enhanced Durability: Operates at temperatures 2x higher than nickel alloys with superior corrosion resistance.
- Energy Efficiency: Reduces manufacturing energy use by up to 90% compared to diffusion bonding.
- Customizable Designs: Enables freeform 3D channels for improved heat transfer and flow performance.
- Embedded Monitoring: Integrated sensors provide real-time data on temperature and strain for proactive maintenance.
- Cost Savings: Lowers production costs by over 30%, with scalable methods suitable for industrial deployment.
Market Applications
- Power Generation: Enhances efficiency in advanced nuclear and concentrated solar power systems.
- Chemical Processing: Enables reliable operations in corrosive and high-temperature environments.
- Metallurgy: Improves heat recovery systems in smelting and refining processes.
- Industrial Safety: Provides continuous monitoring of critical systems via integrated sensors.
INL’s Technology Deployment department focuses solely on licensing intellectual property and collaborating with industry partners who can commercialize our innovations.
We do not engage in purchasing, procurement, or hiring external services for technology development. Our objective is to connect with companies interested in licensing and bringing our technologies to market.
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