High-performance Lower-cost Plastic Heat Exchangers

Metallic Heat exchangers are expensive at lower operating temperatures. This leads to 25 quads of low-level energy (~ $200 billion) wasted annually in the US. In the building sector this causes poor ventilation leading to a sick building syndrome and increased vulnerability to spread of pathogens and virus such as Covid-19. The T2M team is developing a mass producible plastic heat exchanger (P-HEX) which can be extruded at very high-speeds making it affordable for low-level heat. Its very thin walls made of conductive polymer composites make it efficient and cost-effective. The primary goal will be to develop a thermal conductivity enhancing additives for composite polymer formulation suitable for high-speed manufacturing of P-HEX. The heat transfer rates for P-HEX will be further improved by altering the tube shape and flow guides. Beneficial Impacts of P-HEX: Up to 25% Reduction in Energy Use: P-HEX would reduce energy consumption in buildings, industries, transportation and stationery power sectors. Our preliminary estimations show up to 50 billion terms in savings from reduced fuel consumption. Solution for the Sick Building Syndrome and Post-COVID safety: P-HEX provides a cost- effective solution for ventilation to achieve 40 cfm/person while decreasing HVAC bills. Significant Cost Savings to Ratepayers and consumers: The recovered heat by P-HEX translates to $50 billion/yr in savings to the consumers improving the U.S. competitiveness. Supporting Intermittent Renewables: Resulting Natural Gas savings from P-HEX deployment will support intermittency of solar and wind, as well as microgrids needed for resiliency against natural disasters. National Energy Security: The highly efficient P-HEX reduces the dependency imported fossil fuels from politically unstable regions, thus enhancing a sustainable economy. Reduced GHG Emissions: P-HEX recovers process heat without additional harmful emissions. It will strengthen the U.S. position to comply with the Paris Agreement. Job Creation: Deployment of P-HEX will create >50,000 domestic jobs in manufacturing, installation, service and the associated ripple effects (assuming 1 job per GWh saved).