Scalable and compact magnetocaloric heat pump technology

Magnetocaloric heat pumping (MCHP) promises to be more efficient than traditional vapor compression while also eliminating the deleterious effects of gaseous refrigerants. While MCHP devices have shown the temperature spans and efficiencies needed for different heating and cooling applications, they struggle to become commercially viable due to their large size and mass, and resultant high cost. This paper evaluates a baseline MCHP device and explores methods to boost its system power density (SPD). The key components of the baseline system are the gadolinium packed-particle bed active magnetic regenerator (AMR) and a magnetic source composed of permanent magnets and high permeability magnetic steel. To enhance the SPD, the paper evaluates maximizing the AMR volume, opting for first-order magnetocaloric materials, optimizing the magnet and AMR geometry, and reducing the size of magnets and magnetic steel parts. At larger thermal powers, increasing the AMR diameter and the number of magnetic poles were evaluated. Using finite element models, solid models, and estimates of magnetocaloric material performance, thermal powers ranging from 37 W to 44 kW at a nominal 10 K temperature span were projected, and SPD was estimated to improve from 6 W/kg to 81 W/kg. Neglecting end effects, an upper limit of 114 W/g is estimated. Compared to SPD of off-the-shelf compressors with similar environment temperatures, MCHP power density using gadolinium is competitive up to roughly 200 W of cooling power. This is extended to 1 kW when using LaFeSi alloys and up to 3 kW in the limiting case. These results indicate that the performance and mass of MCHP can match that of compressors, which is a critical step toward cost-competitive magnetocaloric technology.