Sustainable Multi-functional And Recyclable heaT-PUMPS

PROJECT OVERVIEW

Smart-Pumps aims to revolutionise heat-pumps’ design and manufacturing.
By leveraging cutting-edge techniques, this Horizon Europe funded research project will design heat-pumps with smart functionalities that are sustainable and efficient. This involves prioritising recycled materials and ensuring component recyclability throughout the heat-pump lifecycle, integrating sensors for performance optimisation, and establishing standardised protocols for mass production. Smart-Pumps seeks a future where heat-pumps’ technology is both environmentally responsible and adaptable, for superior operations and energy saving.

OBJECTIVES

Smart-Pumps will develop innovative, energy saving, highly efficient Heat Pumps (HPs) for residential use.
Smart-Pumps will also design a new manufacturing process to reduce their environmental impact and improve their maintenance.

1. Heat Pumps component redesign for improved performance

Redesigning heat-pumps’ components by redefining the whole heat-pump architecture and operation, aiming at highest possible efficiency, based on extensive analysis and digital experimentation on scenarios with components with different mechanical, thermal and electrical properties.

2. Heat Pumps design for minimal environmental footprint and reduced greenhouse gas emissions

Development of simulation models for the energetic, environmental, and financial analysis of the new heat-pumps; definition of the minimum CO2 footprint, material usage and processing energy of the maximum recyclable rates out of the investigated materials alternatives; estimation of the environmental and financial benefits of the proposed product solutions. These analyses will feed the optimal designs of the new Heat Pumps.

3. Developing and embedding smart properties to HP components

Defining the type of sensors and devices that are needed for HP operational monitoring, digital communication/handling and actuation; defining their optimal placing in HPs and HP components for best performance and minimal complexity during fabrication of HP components. Obtaining sensor data and securely transferring and storing it.

4. Standardised digital manufacturing and testing in HP production

Combining and exploiting synergies in hybrid manufacturing to enable multifunctional parts with embedded smart devices. Handling challenges related to materials with different melting points and structures. Optimising processes, defining testing strategies, and establishing protocols for cost-effective and environmentally friendly monitoring and testing of hybrid manufacturing.

5. Training paths on Digital Manufacturing of smart HPs

Identifying training needs and setting up training modules based on the HP specifications. Developing training paths tailored for the specific needs of different employee groups. The training paths will offer the skills and knowledge needed for safe, competitive and efficient design for Additive/Hybrid Manufacturing, manufacturing monitoring, and HP testing.

EXPECTED OUTCOMES

The proposed innovative Heat Pumps are expected to increase their residential use and help boost Europe’s HP industry, while enhancing their efficiency and therefore assisting the EU in achieving its decarbonisation goals.

1. Improvement in the performance and resilience of heat pump components and overall efficiency

  • Standardised Digital Manufacturing Production Techniques for smart HPs that allow the integration of components combining dissimilar recycled materials.
  • Development of two alternative HPs prototypes embedding smart devices and sensors that enhance operational efficiency.
  • Development of models of Additive Manufacturing (AM) and Hybrid Manufacturing (HM) techniques for minimum production time and maximum component efficiency.
  • Best Practice Guides regarding material choice and optimal process parameter values, dependent on components’ functional characteristics.

2. Reduced environmental footprint during construction of components and HP assembling

  • Creation of standardised testing, manufacturing process and assembly protocols that allow small-scale, on-location manufacturing of HPs, reducing needs for transportation of material and finished product.
  • Development of process protocols for sourcing recycled material and component recyclability.
  • Usage of refrigerants that reduce ozone depletion, global warming, and flammability danger, such as propane.

3. Reduced greenhouse gas emissions from the HP construction and operational life cycle

  • Application of Functionally Graded materials for more energy saving HP components.
  • Development of methodologies to embed sensors and devices within HP components during manufacturing, for optimal monitoring and operating.
  • Development of a novel manufacturing design that incorporates life-cycle parameters for maximum efficiency, sustainability, and reliability.

4. Enhanced energy system integration and significant improvement of overall HP operational efficiency, applicability and flexibility

  • Development of design plans for compact, modular, smart residential HPs, for their more flexible and enhanced adoption.
  • Innovative 3D printing methodologies that allow for local production and material sourcing, reducing costs.

TIMELINE