Polymer Heat Exchangers: An Enabling Technology for Water and Energy Savings

Abstract

Polymer heat exchangers (PHXs), using thermally-enhanced composites, constitute a “disruptive” thermal technology that can lead to significant water and energy savings in the thermoelectric energy sector. This paper reviews current trends in electricity generation, water use, and the inextricable relationship between the two trends in order to identify the possible role of PHXs in seawater cooling applications. The use of once-through seawater cooling as a replacement for freshwater recirculating systems is identified as a viable way to reduce the use of freshwater and to increase power plant efficiency. The widespread use of seawater as a coolant can be made possible by the favorable qualities of thermally-enhanced polymer composites: good corrosion resistance, higher thermal conductivities, higher strengths, low embodied energy and good manufacturability. The authors use several seawater cooling case studies to explore the potential water and energy savings made possible by the use of PHX technology. The results from three case studies suggest that heat exchangers made with thermally enhanced polymer composites require less energy input over their lifetime than corrosion resistant metals, which generally have much higher embodied energy than polymers and polymers composites. Also, the use of seawater can significantly reduce the use of freshwater as a coolant, given the inordinate amounts of water required for even a 1MW heat exchanger.