The challenge

In the FutureKomP project, the LRF is developing a modern and reproducible joining process for highly filled, thermoplastic graphite-polymer composites. While conventional plate heat exchangers (PHEs) are often made of stainless steel or expensive, resource-intensive metals such as titanium in order to avoid product contamination by metal ions, the project offers an economical and sustainable alternative with graphite polyphenylene sulphide (Gr-PPS) and graphite polypropylene (Gr-PP). These composites are PFAS-free, fully recyclable and exhibit a significant reduction in fouling as well as improved cleanability (cleaning-in-place).

The main challenge lies in demonstrating the reliable joinability of the panels required for industrial series production. The existing stainless steel-based geometry of the plates must be optimized in terms of joinability, heat transfer performance and material properties in order to increase the technology readiness level (TRL) from 5 to 6. Particular technical difficulties arise due to the high filling levels of the materials, which influence the melt flow and the heat input during the joining process.

Central elements of the project

• Development of a joining concept by using thermoplastic films as filler material between the embossed composite panels to create defined joining and sealing zones.
• Creation of a material bond for media- and pressure-tight panel stacks by heating in an oven under precisely set contact pressure and holding time.
• Comprehensive validation through micrograph analyses, visual inspections of the weld seams, a hydrostatic pressure test up to 10 bar as a binding acceptance criterion and the determination of heat transfer coefficients and pressure loss characteristics on the test bench.
• Commercialization strategy with systematic registration of property rights such as patents and utility models as well as the preparation of a spin-off for market penetration.