How They Make It Work – Precision Micro’s Chemical-Etched Heat Exchanger Flow Plates
‘How They Made it Work’ is a column that features some of the latest technological advancements in the chemical process industry. Here, Chemical Processing asks experts from various technology providers to provide insight into their innovations and how they're helping chemical manufacturers operate their plants more efficiently and effectively.
Technology
Precision Micro’s chemical-etched components were designed to help engineers build the next generation of compact, high-performance heat exchangers for chemical processing and clean energy systems. Using a process called photochemical machining (PCM), metal is selectively dissolved through controlled chemical reactions to form intricate flow channels and geometries without mechanical stress or burrs.
The result is precise, corrosion-resistant plates that perform reliably in high-temperature, high-pressure and corrosive conditions. Because designs come straight from CAD-generated digital tooling, prototypes and adjustments can be produced in a few days.
Development, Design and Purpose
This technology was developed in response to growing demand for faster and more flexible ways to manufacture compact heat exchanger plates and flow channels. This comes as conventional methods, like stamping or machining can distort material, limit design freedom and slow down development.
Photochemical etching has been designed to eliminate these issues, enabling the production of intricate flow patterns in thinner, more compact designs than those achievable with traditional manufacturing techniques.
By applying a photoresist mask and using chemistry to dissolve metal in exact locations, the process can create extremely fine features and consistent microchannels. This can potentially improve heat transfer and material integrity.
Significance in Chemical Plants
In chemical processing, heat exchangers are essential for maintaining stable temperatures, safe operation and overall process efficiency. Photochemical etching enables the production of stress-free, burr-free metal parts that resist corrosion and deliver consistent thermal performance. This precision supports the manufacture of printed circuit heat exchangers (PCHEs), which are compact, lightweight and highly efficient alternatives to conventional shell-and-tube designs.
The etched flow channels create large surface areas, which can enable improved heat transfer, while diffusion-bonded construction withstands extreme pressures and temperatures. PCHEs also use materials, such as stainless steel, titanium and other durable alloys to ensure long service life and corrosion resistance.
Therefore, for plants focused on reducing energy use, saving space and improving uptime, etched PCHEs offer a reliable way to modernise systems and support long-term sustainability goals.
Unique Features
- No mechanical or thermal stress
- Ability to produce channels as fine as 25 microns, giving engineers design freedom to optimize fluid flow and thermal transfer
- Utilization of digital CAD data rather than physical tooling, allowing for changes to be made quickly and economically.
Real-World Example
In the energy sector, PCHEs are used in applications such as the cooling and liquefaction of natural gas, precooling of hydrogen in refueling stations and carbon capture in renewable energy systems. At hydrogen refueling stations, rapid refueling requires efficient cooling of highly compressed and heated hydrogen gas. PCHEs, with chemically etched flow channels, can offer a more compact, higher-efficiency solution.
The diffusion-bonded plates form a solid metal structure capable of withstanding very high pressures, allowing rapid gas cooling.
About the Author
Ben Kitson
Ben Kitson, head of business development at Precision Micro, is a creative and strategic manager with over 20 years’ experience in direct major customer relationship development and maximisation of the profit line. He is adept at nurturing current business, identifying prospective opportunities and project managing challenging situations.