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Title: Manufacturing Process Development for Lower-Cost Heat Exchangers in High-Temperature/Pressure Applications

; ;
Publication Date:
Research Org.:
Brayton Energy LLC
Sponsoring Org.:
USDOE Office of Fossil Energy (FE)
OSTI Identifier:
Report Number(s):
NETL 2017-05-19-DE-FE0024020-Final Technical Report
DOE Contract Number:
Type / Phase:
Resource Type:
Technical Report
Country of Publication:
United States
20 FOSSIL-FUELED POWER PLANTS; supercritical CO2, Heat Exchangers, Compact, high pressure, high temperature, extended surface, unit-cell

Citation Formats

Nash, James, Caruso, William, and Farias, Jason. Manufacturing Process Development for Lower-Cost Heat Exchangers in High-Temperature/Pressure Applications. United States: N. p., 2017. Web.
Nash, James, Caruso, William, & Farias, Jason. Manufacturing Process Development for Lower-Cost Heat Exchangers in High-Temperature/Pressure Applications. United States.
Nash, James, Caruso, William, and Farias, Jason. 2017. "Manufacturing Process Development for Lower-Cost Heat Exchangers in High-Temperature/Pressure Applications". United States. doi:.
title = {Manufacturing Process Development for Lower-Cost Heat Exchangers in High-Temperature/Pressure Applications},
author = {Nash, James and Caruso, William and Farias, Jason},
abstractNote = {},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = 2017,
month = 5

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  • The overall goal of this project is to support Idaho National Laboratory in developing a new advanced high temperature multi fluid multi loop test facility that is aimed at investigating fluid flow and heat transfer, material corrosion, heat exchanger characteristics and instrumentation performance, among others, for nuclear applications. Specifically, preliminary research has been performed at The Ohio State University in the following areas: 1. A review of fluoride molten salts’ characteristics in thermal, corrosive, and compatibility performances. A recommendation for a salt selection is provided. Material candidates for both molten salt and helium flow loop have been identified. 2. Amore » conceptual facility design that satisfies the multi loop (two coolant loops [i.e., fluoride molten salts and helium]) multi purpose (two operation modes [i.e., forced and natural circulation]) requirements. Schematic models are presented. The thermal hydraulic performances in a preliminary printed circuit heat exchanger (PCHE) design have been estimated. 3. An introduction of computational methods and models for pipe heat loss analysis and cases studies. Recommendations on insulation material selection have been provided. 4. An analysis of pipe pressure rating and sizing. Preliminary recommendations on pipe size selection have been provided. 5. A review of molten fluoride salt preparation and chemistry control. An introduction to the experience from the Molten Salt Reactor Experiment at Oak Ridge National Laboratory has been provided. 6. A review of some instruments and components to be used in the facility. Flowmeters and Grayloc connectors have been included. This report primarily presents the conclusions drawn from the extensive review of literatures in material selections and the facility design progress at the current stage. It provides some useful guidelines in insulation material and pipe size selection, as well as an introductory review of facility process and components.« less
  • An economic comparison is presented of three conceptual process heat reactor plants. Results are presented and discussed.
  • In April 1974, the United States Atomic Energy Commission (USAEC) authorized General Atomic Company, General Electric Company and Westinghouse Astronuclear Laboratory to assess the available technology for producing process heat utilizing very high temperature nuclear reactors. General Electric and Westinghouse produced concepts for the entire nuclear system, including the balance of plant. The General Atomic assessment included only the nuclear reactor portion of the nuclear plant. United Engineers and Constructors Inc. (UE and C) was requested by the USAEC in November 1974 to prepare an economic comparison of the three conceptual plants. The comparison is divided into three tasks: (1)more » Develop a balance of plant conceptual design to be combined with the General Atomic concept as a basis for comparison, and estimate the cost of the General Atomic/UE and C concept in July 1974 dollars; (2) Normalize the overall plant costs for the General Atomic/UE and C, General Electric and Westinghouse concepts, compare the costs, and identify significant differences between the concepts; and (3) Estimate the operation and maintenance costs for the General Atomic/UE and C plant and compare with the other concepts. The results of these task studies are discussed.« less
  • Designed and tested silicon carbide to metal joining and silicon carbide joining technology under high temperature and high pressure conditions. Determined that the joints maintained integrity and remained helium gas tight. These joined parts have been tested for mechanical strength, fracture toughness and hermeticity. A component testing chamber was designed and built and used for testing the joint integrity.
  • Two 500-kw fused-fluoride-to-NaK heat exchangers, two 500-kw NaK-to-air radiators, and a 20-tube highvelocity heat exchanger were fabricated for a heatexchanger development program. A construction procedure, utilizing both inert-arc-welding and hightemperature dry-hydrogen brazing, was used successfully on all of the units. The tube-to-header joints were welded and back-brazed; the manifold joints were inertarc-welded with full penetration; and the tube-to-fin joints were brazed. A detailed description of the fabrication of each type of component is discussed and a cost analysis of the 500-kw units is presented. (auth)