SUSTAINABLE MULTI-FUNCTIONAL AND RECYCLABLE HEAT PUMPS

Informazioni relative al progetto

Smart-Pumps

ID dell’accordo di sovvenzione: 101147440

DOI

10.3030/101147440

Data della firma CE 28 Marzo 2024

Data di avvio 1 Giugno 2024

Data di completamento 31 Maggio 2027

Finanziato da

• Climate, Energy and Mobility

Costo totale

€ 1 999 952,50

Contributo UE

€ 1 999 952,50

Coordinato da

ELLINIKO MESOGEIAKO PANEPISTIMIO
Greece

Periodic Reporting for period 1 - Smart-Pumps (SUSTAINABLE MULTI-FUNCTIONAL AND RECYCLABLE HEAT PUMPS)

Periodo di rendicontazione: 2024-06-01 al 2025-11-30

Sintesi del contesto e degli obiettivi generali del progetto

The EU has set ambitious targets to reduce energy imports in response to geopolitical instability in Northeast Europe. Heat pumps (HPs) are a key technology for decreasing dependence on imported fossil fuels, with large-scale deployment expected to cut gas demand in buildings by about 40% by 2030 compared to 2022 and reduce the EU energy import bill by approximately €60 billion over the same period. Achieving these targets under the REPowerEU strategy requires addressing high production costs, supply chain bottlenecks, skills shortages, and power sector integration. Strengthening EU-based manufacturing capacity through a focused industrial strategy for HP components and assembly is therefore critical.
HP efficiency is constrained not only by thermodynamic limits but also by conventional design and manufacturing practices. Current HPs typically reach no more than 35% of their theoretical maximum efficiency, largely due to single-material, single-function component architectures. In heat exchangers, efficiency gains are pursued through extended piping and finned surfaces, increasing system volume, pressure drops, and mechanical and thermal losses across operating conditions. These drawbacks are exacerbated by space, noise, reliability, and installation constraints, particularly in residential applications. At the same time, the Kigali Amendment and EU F-gas Regulation impose strict requirements on refrigerant use, reinforcing the need to minimize refrigerant charge and losses.
Although advanced control devices improve operation near optimal conditions, they cannot overcome structural limitations of conventional component designs. Improving efficiency, sustainability, affordability, safety, and circularity therefore requires a paradigm shift toward circular-by-design HP components integrating advanced geometries, multifunctionality, embedded sensing, digital manufacturing, and recycled materials.
The Smart-Pumps approach addresses these challenges through five coupled actions: (1) redesigning HP components using Design for Additive/Hybrid Manufacturing (DfA/HM), integrating operational and life-cycle parameters; (2) applying Functionally Graded Material concepts to tailor thermal, mechanical, and electrical properties; (3) embedding sensors and smart devices for real-time monitoring and adaptive control; (4) defining standardized testing, manufacturing, and assembly protocols to support scalability; and (5) developing training curricula for digital design, manufacturing, and testing. The focus is on residential air-to-water and water-to-water HPs using propane (R290), with compact, modular components enabling flexible installation and system upscaling.
Smart-Pumps delivers solutions applicable across EU climates and compatible with smart building ecosystems and interconnected HP networks. Through standardization and validation, the project establishes a foundation for next-generation HP components and informs future EU directives, targeting at least 25% reduction in production-related environmental footprint, over 30% reduction in operational energy consumption and refrigerant use, and long-term productivity gains exceeding 15% by 2030 and 30% by 2040.

Lavoro eseguito dall’inizio del progetto fino alla fine del periodo coperto dalla relazione e principali risultati finora ottenuti

Smart-Pumps’ primary objective is to develop innovative heat pumps (HPs) by implementing standardizable design, manufacturing, and testing methodologies for low-environmental-footprint, high-efficiency smart HPs that are reliable, affordable, and safe, and manufactured using recycled materials, thereby strengthening the competitiveness, circularity, and sustainability of the EU HP manufacturing sector.
Up to month 18, the following activities were performed:
WP1: Technical requirements and specifications for sustainable smart HPs were defined, covering component design, materials, manufacturing readiness, and sensor integration. State-of-the-art HP systems, components, sensors, controllers, and connectivity solutions for residential applications (4–15 kW) were reviewed. Stakeholder requirements from end users, installers, and manufacturers were translated into functional and regulatory constraints. Materials for Additive and Hybrid Manufacturing were assessed, focusing on recycled metallic powders and functional grading. Digital design and multiphysics simulation workflows were established for topology-optimized, multi-material components. Capabilities and limitations of laser-based Directed Energy Deposition and Hybrid Additive–Subtractive processes were analyzed. Sensor selection, placement, protection, and connectivity were evaluated. Life-cycle analysis and costing of commercial HPs were conducted to establish benchmarks.
WP2: Advanced sensing, control, and connectivity solutions were developed, focusing on real-time monitoring of two-phase refrigerant flow. A non-invasive ultrasonic sensor for liquid–gas phase fraction measurement was designed and tested, and machine-learning models were trained using ultrasonic, temperature, and pressure data. Integrated sensing–actuation modules, cloud connectivity, user dashboards, and control scenarios were implemented. Two smart domestic HP concepts (air-to-water and water-to-water) using R290 were developed and analyzed using a methodology combining DfA/HM, CFD, FEA, and thermodynamic modeling. Advanced heat exchangers, internal heat exchangers, and consolidated hydraulic components were redesigned. Copper alloy powders were characterized for AM suitability, and Functionally Graded Materials were numerically investigated. Baseline commercial HPs were modeled, and grid-aware control and smart valving concepts were evaluated through simulations.
By month 18, the following achievements were realized:
WP1: A coherent specification framework for smart HPs under DfA/HM was established. Performance bottlenecks and efficiency improvement paths were identified. Design-level feasibility of recycled and functionally graded materials was demonstrated, and manufacturing-ready design and sensor embedment guidelines were defined. Benchmark environmental and cost metrics were produced.
WP2: A plug-and-play ultrasonic sensing solution for accurate refrigerant quality estimation was achieved. ML-based phase prediction improved diagnostics and operational awareness. Integrated sensing, actuation, and cloud connectivity enabled real-time optimization and enhanced safety. Gyroid and optimized internal heat exchangers showed reduced approach temperatures and pressure losses, enabling predicted COP gains of ~11–13% for air-to-water and ~22–23% for water-to-water HPs. Functional grading reduced thermal stress and heat losses. Complete CAD models of both optimized HP variants were delivered, establishing a validated, high-efficiency, and sustainable design framework.

Progressi oltre lo stato dell’arte e potenziale impatto previsto (incluso l’impatto socioeconomico e le implicazioni sociali più ampie del progetto fino ad ora)

Novel designs of gyroid heat exchangers, internal heat exchanger (subcool-superheat) and consolidated distributor/collector with embedded valves and temperature sensor.