Additively Manufactured Modular Heat Exchanger Accommodating High Pressure, High Temperature and Corrosive Fluids

A heat exchanger module adapted to receive high temperature, high pressure, and corrosive fluids, the heat exchanger module comprising:

• a plurality of heat exchangers, each heat exchanger in the plurality of heat exchangers includes:
• a body;
• a first set of channels integrally formed through the body;
• a first set of headers integrally formed with the body and fluidly coupled to the first set of channels;
• a second set of channels integrally formed through the body;
• and
• a second set of headers integrally formed with the body and fluidly coupled to the second set of channels;
• wherein, a first heat exchanger of the plurality of heat exchangers is fluidly coupled to a second heat exchanger of the plurality of heat exchangers (a) in series, (b) in parallel, or (c) in series and parallel.

A method of manufacturing a heat exchanger using additive manufacturing, the method comprising:

• (a) creating, via a modeling application, a model of the heat exchanger based on a set of parameters, the molding application being stored on a memory of a computing device and executed on a processor of the computing device;
• (b) distributing a layer of powder on a building platform;
• (c) selectively applying a binding agent, via a carriage, to the layer of powder based at least in part on the model of the heat exchanger created by the modeling application thereby creating a printing area, where some particles in the layer of powder are bound together via the binding agent, and a material area, where each particle in the layer of powder is separate from each other particle in the layer of powder;
• (d) translating the building platform in a direction away from the carriage by a distance, the distance being greater than a thickness of the layer of powder;
• (e) repeating steps (b)-(d) until the heat exchanger is formed.