Cost of Using Laser Powder Bed Fusion to Fabricate a Molten Salt-to-Supercritial Carbon Dioxide Heat Exchanger for Concentrating Solar Power

Ziev, Tracey; Rasouli, Erfan; Tano, Ines-Noelly; Wu, Ziheng; Rao Yarasi, Srujana; Lamprinakos, Nicholas; Seo, Junwon; Narayanan, Vinod; Rollett, Anthony D.; Vaishnav, Parth

doi:10.1089/3dp.2022.0188

Cost of Using Laser Powder Bed Fusion to Fabricate a Molten Salt-to-Supercritial Carbon Dioxide Heat Exchanger for Concentrating Solar Power

Journal Article · Thu Mar 02 00:00:00 EST 2023 · 3D Printing and Additive Manufacturing

DOI:https://doi.org/10.1089/3dp.2022.0188· OSTI ID:2441279

^[1]; Rasouli, Erfan ^[2]; Tano, Ines-Noelly ^[2]; Wu, Ziheng ^[3]; Rao Yarasi, Srujana ^[4]; ^[4]; Seo, Junwon ^[4]; Narayanan, Vinod ^[2]; Rollett, Anthony D. ^[4]; ^[5]

Carnegie Mellon University, Pittsburgh, PA (United States); University of Michigan
University of California, Davis, CA (United States)
Carnegie Mellon University, Pittsburgh, PA (United States); Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
Carnegie Mellon University, Pittsburgh, PA (United States)
Carnegie Mellon University, Pittsburgh, PA (United States); University of Michigan, Ann Arbor, MI (United States)

Advances in manufacturing technologies and materials are crucial to the commercial deployment of energy technologies. We present the case of concentrating solar power (CSP) with molten salt (MS) thermal storage, where low-cost, high-efficiency heat exchangers (HXs) are needed to achieve cost competitiveness. Here, the materials required to tolerate the extreme operating conditions in CSP systems make it difficult or infeasible to produce them using conventional manufacturing processes. Although it is technically possible to produce HXs with adequate performance using additive manufacturing, specifically laser powder bed fusion (LPBF), here we assess whether doing so is cost-effective. We describe a process-based cost model (PBCM) to estimate the cost of fabricating a MS-to-supercritical carbon dioxide HX using LPBF. The PBCM is designed to identify modifications to designs, process choices, and manufacturing innovations that have the greatest effect on manufacturing cost. Our PBCM identified HX design and LPBF process modifications that reduced projected HX cost from $$\$$750$ per kilo-Watt thermal (kW-th) ($$\$$8$$ /cm³) to $$\$$350$ /kW-th ($$\$$6/$ cm³) using currently available LPBF technology, and down to $$\$$220$ /kW-th ($$\$$4$$ /cm³) with improvements in LPBF technology that are likely to be achieved in the near term. The PBCM also informed a redesign of the HX design that reduced projected costs to $$\$$140$ –160/kW-th ($$\$$3$$ /cm³).

View Accepted Manuscript (DOE)

Research Organization:: University of California, Davis, CA (United States)

Sponsoring Organization:: USDOE Advanced Research Projects Agency - Energy (ARPA-E); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Renewable Power Office. Solar Energy Technologies Office

Grant/Contract Number:: AR0001127; EE0008536

OSTI ID:: 2441279

Journal Information:: 3D Printing and Additive Manufacturing, Journal Name: 3D Printing and Additive Manufacturing Journal Issue: 3 Vol. 11; ISSN 2329-7662

Publisher:: Mary Ann Liebert, Inc.Copyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
additive manufacturing
concentrating solar power
molten salt-to-supercritial carbon dioxide
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techno-economic modeling

Cost of Using Laser Powder Bed Fusion to Fabricate a Molten Salt-to-Supercritial Carbon Dioxide Heat Exchanger for Concentrating Solar Power

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