(20b) Two Key Challenges for Microchannel Process Technology: Validated Cost of Manufacturing and Manufacturing Infrastructure

Microchannel process technology (MPT) as a platform for process intensification has been investigated for a broad range of applications and unit operations, including heat exchangers, microreactors, and separations.  Several research groups have designed, built, and demonstrated devices utilizing a prototyping process consisting of photochemical machining to pattern metal shims and diffusion brazing to bond stacks of shims to form a device.  Alternative processes have been explored that are perceived to be more amenable to high volume production, including stamping, low-temperature brazing, and laser welding.  While the performance and utility of MPT devices have been repeatedly demonstrated in the laboratory and technologies are penetrating specific markets, questions remain about the economic viability of MPT for broader markets, particularly those that are more cost sensitive.  The two key challenges for answering these questions are validated cost of goods sold for high volume manufacturing and establishing a manufacturing infrastructure.  Progress is being made with the first challenge using process-based cost modeling methodologies and validation by equipment suppliers and manufacturers.  Alternative scenarios for establishing a manufacturing infrastructure are discussed.  A number of case studies for specific devices and applications are described.