Advancing 3D-Printed Heat Exchangers in the DESOLINATION Project: A Milestone at LUT University

Advancing 3D-Printed Heat Exchangers in the DESOLINATION Project: A Milestone at LUT University

As part of the DESOLINATION project’s ongoing mission to decarbonize the desalination process, a major milestone has been achieved at LUT University: the experimental validation of a 3D-printed heat exchanger. This breakthrough demonstrates that additive manufacturing (also known as 3D printing) can significantly enhance the performance of heat exchangers used in supercritical carbon dioxide (sCO2) Brayton cycles, paving the way for more efficient energy systems.

Recently, the DESOLINATION project team reached a major milestone by successfully validating their experimental setup at LUT University. This validation process involved several key steps:

  1. Design: The team developed a blueprint for the 3D-printed heat exchanger, focusing on optimizing its shape and function.
  2. Simulation: Using tools like Computational Fluid Dynamics (CFD), the team simulated how the heat exchanger would perform under real-world conditions.
  3. Additive Manufacturing: The heat exchanger was printed using advanced 3D printing techniques, allowing for a more intricate and efficient design.
  4. Assembly: The printed parts were then assembled into a fully functional heat exchanger.
  5. Testing: The final step was to test the heat exchanger to ensure it could withstand the pressures and temperatures expected in the sCO2 Brayton cycle.

The successful completion of these steps demonstrates that 3D-printed heat exchangers can perform effectively in high-pressure, high-temperature environments. This breakthrough marks an important step toward integrating these advanced designs into real-world concentrating solar power (CSP) systems.

What This Means for the Future of Sustainable Energy

The ability to use 3D-printed heat exchangers in sCO2 Brayton cycles has far-reaching implications for the DESOLINATION project and beyond. By improving the efficiency of energy conversion, these innovations will make it easier to generate clean electricity from renewable sources like solar power. This is particularly important for the project’s goal of decarbonizing desalination, which requires large amounts of energy to produce fresh water in arid regions.

The Role of Heat Exchangers in Desalination and Energy Generation

Heat exchangers are crucial in systems that convert heat into usable energy. In the DESOLINATION project, they are key components in the sCO2 Brayton cycle, a thermodynamic process that uses heat to generate electricity. When combined with concentrating solar power (CSP)—which concentrates solar energy to produce high levels of heat—these systems offer a more efficient way to produce power while reducing carbon emissions.

However, creating heat exchangers that can handle the extreme conditions required by sCO2 Brayton cycles (temperatures up to 600°C and pressures around 250 bars) presents significant challenges. That’s where additive manufacturing comes in.

Additive Manufacturing: A Game Changer for Heat Exchanger Design

Traditional manufacturing techniques often limit the design of heat exchangers, making it difficult to optimize them for maximum efficiency. Additive manufacturing, or 3D printing, solves this problem by allowing engineers to create more complex designs that would be impossible with conventional methods.

In the DESOLINATION project, the team used 3D printing to create highly specialized heat exchangers that are better suited to the high-pressure, high-temperature conditions of the sCO2 Brayton cycle. These new designs are expected to improve the overall efficiency of the system, making it more effective at converting solar energy into electricity.

As DESOLINATION moves forward, the continued development and testing of 3D-printed heat exchangers will play a crucial role in creating more sustainable, efficient energy systems. With each milestone, the project is getting closer to its vision of a world where desalination is powered by clean, renewable energy. By combining cutting-edge technologies like additive manufacturing and advanced thermodynamic processes, the DESOLINATION project is paving the way for a greener, more water-secure future.

Pushing the Limits of Heat Exchanger Design with CFD in the DESOLINATION Project

Pushing the Limits of Heat Exchanger Design with CFD in the DESOLINATION Project

The DESOLINATION project, funded by the European Union’s Horizon 2020 program, is making remarkable strides in its mission to decarbonize desalination. One of the most exciting developments comes from our work on optimizing heat exchangers for use in supercritical carbon dioxide (sCO2) Brayton cycles. These innovations could revolutionize how we generate power from renewable energy sources like solar power. Here’s a closer look at how Computational Fluid Dynamics (CFD) is playing a key role in this effort.
The Role of CFD: Optimizing Heat Exchanger Performance

Designing heat exchangers that can operate under these extreme conditions is no small feat. To ensure the best possible design, DESOLINATION is using Computational Fluid Dynamics (CFD)—a powerful computer tool that models how fluids flow and how heat is transferred in complex systems.

CFD allows the project team (particularly TEMISTh) to simulate the performance of the heat exchanger in a virtual environment. This includes analyzing key factors such as:

  • Thermal efficiency: How well the exchanger transfers heat from one fluid to another.
  • Pressure drop: The reduction in pressure that occurs as the fluid flows through the heat exchanger, which can impact overall system performance.
  • Thermomechanical constraints: The structural stresses the exchanger must withstand at high temperatures and pressures.

By using CFD, the team can find the optimal balance between thermal efficiency and pressure drop, ensuring the heat exchanger performs well while remaining durable.

What Are Heat Exchangers and Why Are They Important?

A heat exchanger is a device that transfers heat from one fluid (either a liquid or gas) to another. In energy systems, they are essential for converting heat into usable power. In the DESOLINATION project, the goal is to create highly efficient heat exchangers that can operate under extreme conditions—temperatures as high as 600°C and pressures up to 250 bars. These conditions are required for a supercritical carbon dioxide (sCO2) Brayton cycle, a process that uses heat to generate electricity more efficiently than traditional steam cycles.

Real-World Testing at King Saud University

After fine-tuning the design using CFD, the next step is real-world testing. The team plans to run these heat exchangers for 4,000 hours at a pilot plant in King Saud University. These tests will move the project closer to Technology Readiness Level (TRL) 7, meaning the technology will be ready for deployment in real-world systems.

The Role of CFD: Optimizing Heat Exchanger Performance

The preliminary results from these simulations are promising. The team believes that their designs could push the limits of what’s possible for heat exchangers in sCO2 Brayton cycles. If successful, these innovations will pave the way for more efficient concentrating solar power (CSP) plants, where solar energy is concentrated to generate high levels of heat, which can then be used to produce electricity.

CFD: More Than Just an Engineering Tool

Beyond its technical capabilities, CFD has also proven to be a powerful communication tool. The simulations it creates provide visually engaging representations of how heat and fluids move through the system, making it easier to explain the science behind the project to a broader audience.

By using CFD to design and optimize these cutting-edge heat exchangers, the DESOLINATION project is taking a huge step toward more sustainable and efficient energy systems, bringing us closer to a future where desalination can be powered by clean, renewable energy.

DESOLINATION Shines at EuroMembrane 2024: Showcasing Cutting-Edge Research in Forward Osmosis Membranes

DESOLINATION Shines at EuroMembrane 2024: Showcasing Cutting-Edge Research in Forward Osmosis Membranes

The DESOLINATION project made a remarkable impact at this year’s EuroMembrane Conference, a leading international event in membrane science and technology. Held in 2024, the conference brought together experts from around the world to share insights and explore the latest advancements in membrane technologies, particularly for water treatment and desalination applications.

We are proud to highlight that Aylin Kınık, from the Membrane Materials and Processes research group at Eindhoven University of Technology, represented the DESOLINATION project with an impressive poster presentation. Her research, conducted with professors Zandrie Borneman and Kitty Nijmeijer, explored the “Impact of Pluronic as Draw Solution on LbL-Membranes in Forward Osmosis (FO),” offering new perspectives on how these solutions can enhance membrane efficiency in desalination technologies. This cutting-edge work has sparked significant interest, contributing valuable insights into the future of sustainable water treatment.

The event provided an excellent platform for the DESOLINATION project to share these advancements with a global audience, further solidifying its role in shaping the future of membrane technologies. The breakthroughs presented at EuroMembrane 2024 showcase the project’s commitment to addressing critical challenges in water scarcity and sustainable desalination.

In addition, our project partner Tekniker (represented by Mailen Argaiz, see picture) presented their innovative research on thin-film composite membranes developed with electrospun nanofibers and graphene oxide (GO). Their findings demonstrated notable improvements in water flux (Jw) and salt rejection (Js)—key performance indicators for making forward osmosis membranes more effective in desalination processes.

Thank you to everyone who connected with us during the event and engaged with our research. Stay tuned for more innovations from the DESOLINATION team as we continue to push the boundaries of membrane science for a more water-secure world!

Membrane Processes: A Solution for Modern Challenges

The Role of Research and Innovation

Membrane processes are at the forefront of addressing some of the most pressing issues of our time. From water purification and wastewater treatment to energy production and environmental protection, these technologies offer sustainable and efficient solutions. The DESOLINATION project is proud to showcase its advancements in this field at Euromembrane 2024, highlighting the transformative potential of membrane processes.

Research and innovation are critical in driving the development of membrane technologies. By fostering collaboration between academia and industry, we can accelerate the discovery of new materials and processes that enhance performance and reduce costs. The Euromembrane 2024 conference provides a unique platform for sharing knowledge, discussing challenges, and exploring future directions in membrane research. Join us as we delve into the latest breakthroughs and their applications in solving today’s global challenges.

Simultaneous design optimization of binary co2-mixture-based power cycles for concentrated solar power applications

Simultaneous design optimization of binary co2-mixture-based power cycles for concentrated solar power applications

In the push toward cleaner and more efficient energy, concentrated solar power (CSP) systems have emerged as a promising contender. But their potential has been limited by the need for innovative, cost-effective solutions to convert solar heat into electricity.

We’re thrilled to announce a groundbreaking publication by Teesside University, one of our partners, presented at the ASME (The American Society of Mechanical Engineers) Turbo Expo 2024 (Turbomachinery Technical Conference and Exposition).

This work unveils an innovative approach to optimizing power cycles for CSP systems, driving advancements in efficiency and sustainability.

A recent study introduces an innovative approach to improving power cycles for concentrated solar power (CSP) systems, a key technology in the renewable energy landscape. This research focuses on optimizing the performance of systems that use CO₂-based mixtures as working fluids, offering significant advancements in efficiency, cost-effectiveness, and adaptability to various operating conditions.

Traditionally, CSP systems rely on converting solar heat into electricity through power cycles. This study enhances that process by developing a simultaneous optimization strategy. It considers the design of the power cycle, the selection of chemical additives (dopants), and the specific composition of the CO₂-based working fluids. By analyzing these factors together, the researchers aim to maximize system efficiency while reducing costs.

The study tests these innovations under realistic scenarios, including two operating temperature ranges: 550°C, typical of current CSP systems, and a higher 700°C for advanced designs. It also accounts for ambient temperatures of 30°C, 35°C, and 40°C, reflecting the diverse environments where CSP systems operate.

One of the key breakthroughs is the use of binary mixtures of CO₂ combined with chemical dopants like sulfur dioxide (SO₂) or acetonitrile (C₂H₃N). These additives enhance the thermodynamic properties of the working fluid, allowing the system to perform more effectively under varying conditions. The research team employed advanced modeling techniques to evaluate these mixtures, ensuring precise predictions of their performance.

Optimization in this context focuses on two main objectives: maximizing thermal efficiency (the amount of solar energy converted into electricity) and improving specific work (the energy produced per unit of working fluid). These improvements reduce the size and cost of system components, like power blocks and thermal energy storage (TES), making CSP systems more economically viable.

This innovative approach holds great promise for the future of renewable energy. By addressing technical and financial challenges, the study opens the door for CSP systems to play a larger role in the global transition to cleaner energy. With its flexible methodology, capable of incorporating new materials and designs, this research sets the stage for continued advancements in solar power technology.

Preliminary Characterization of the Desolination Project Demo Plant: Design and Off-Design Operability

Preliminary Characterization of the Desolination Project Demo Plant: Design and Off-Design Operability

The DESOLINATION project, a beacon of innovation in renewable energy, has taken a major step forward with the preliminary performance analysis of its demonstration plant.

Recently unveiled at the ASME Turbo Expo 2024, this work brings together the expertise of TEMISth, UNIBS (University of Brescia), and Politecnico di Milano (POLIMI) to explore the potential of a novel power cycle built for sustainability and efficiency.

What makes this Demo Plant unique?

This demo plant operates a simple recuperative transcritical power cycle, a system that sets new standards in energy conversion. Here’s what makes it stand out:

  • Innovative Working Fluid: Instead of conventional fluids, the plant uses a mixture of CO₂ and SO₂, selected for its unique thermodynamic properties.
  • Adapted to Harsh Conditions: Designed to thrive in environments with high solar radiation and elevated ambient temperatures, this air-cooled system mirrors real-world challenges faced by Concentrated Solar Power (CSP) plants.
Key features of the cycle
  • Powerful yet Compact: At the heart of the system is an axial turbine handling a flow rate of 0.2 m³/s, enabling a power output of 1.8 MWel.
  • Next-Gen Heat Exchangers: Equipped with gyroid-structured recuperators and heat exchangers, these components maximize thermal transfer while minimizing material use.
  • Modeling Precision: Advanced simulations in MATLAB, enhanced by Computational Fluid Dynamics (CFD) results, ensure the system is optimized for both design and off-design conditions.
How efficient is it?

Efficiency is key for renewable energy systems, and the DESOLINATION demo plant doesn’t disappoint. By operating in a sliding pressure mode, the cycle achieves impressive efficiencies of over 30%, even when running at partial load.

Adapting to changing temperatures

One of the standout features of this system is its ability to handle varying ambient conditions:

  • At high ambient temperatures (above 30°C), the cycle functions seamlessly, thanks to fixed-speed condenser fans.
  • At lower temperatures (around 10°C), the air velocity can be adjusted to ensure optimal operation.
Handling the system’s inventory

The study also delves into the plant’s piping system, revealing that the total fluid inventory is heavily influenced by the condenser’s operation. Adjustments in fluid storage of up to 300 kg are required to maintain stability when switching between different temperature conditions.

This research represents a significant milestone in the DESOLINATION project’s mission to develop renewable energy systems that are not only efficient but also adaptable to a variety of real-world conditions. By bridging the gap between innovative design and practical application, the demo plant is a glimpse into the future of clean, sustainable power generation.