Mission Short

Merging the realm of synthetic biology and engineering to power the future with efficiency.

The Challenge

Liquid-to-air heat exchangers operate in open environments, leaving their surfaces exposed to dust, sediment, and airborne microorganisms which gradually impair their performance. As such dust and sediment over time form an insulating layer on the heat-conducting surfaces, which has been associated with a 30% decrease in heat conductivity. Natural corrosion further reinforces this issue through decreasing conductivity by 20%. These effects can be even more drastic under higher temperatures. However, an even more pressing issue is biofouling. This refers to the process by which bacteria adhere to the surfaces, forming a slimy layer, referred to as a biofilm. Not only does this bacterial layer drastically reduce thermal conductivity, but it also accelerates corrosion through the deposition of organic substances. A biofilm as thick as a single strand of hair (0.1 mm) has been shown to decrease the thermal conductivity of copper plates by 98%. It is clear that these environmental influences are detrimental to the efficiency of heat exchangers. This loss in efficiency is compensated for by the system working overtime, consuming more energy, and thereby producing more greenhouse gases in the process. Currently, these issues are tackled through recurrent cleaning of heat exchanger surfaces, which employs harsh chemicals – an unnecessary burden for both humans and our environment. This introduces downtime and leads to increased operational costs. With rising expenses, companies most often opt for the decommissioning of conducting sheets and pipes, producing unnecessary waste in the process and further exploiting our planet for its resources.

The solution

CoreSpin aims to solve the burning issue of biofouling and the deposition of dust and sediment through coating these heat-conducting surfaces with an innovative and sustainable nano-layer made from engineered spider silk proteins. While some spiders are able to produce various types of silk, dragline silk as the load-bearing element of the spider web is of particular interest. Dragline silk is made up of specific proteins, which are well known for their outstanding mechanical properties, being as strong as steel and five times more elastic than nylon. These characteristics arise from their unique architecture within the silk fibre. However, for our project this protein structure extends beyond just mechanical aspects, as the ordered structure of spider silk proteins also allows for thermal conductivity along the fibre. We aim to leverage the intrinsic thermal conductivity of spider silk proteins to create a nano-layer which will allow for thermal conductivity beyond the metal-protein interface. Further, the proposed layer features a specific surface topography of nanopillars which prevents bacterial adhesion and thereby the process of biofilm formation. Simultaneously, this structure is hypothesised to have a self-cleaning effect which will mitigate the build up of dust and sediment. Thereby, CoreSpin is able to provide a holistic, bio-engineered solution to maintain long-term heat exchanger performance. As such, our project aims to extend a field which traditionally is dominated by material science and mechanical engineering through an innovative approach grounded on biological principles, reflecting the interdisciplinary innovation that drives sustainability. By maintaining thermal conductivity and preventing the collective effects of biofouling, dust, and sediment, our approach has the potential to cut unnecessary energy waste, lower greenhouse gas emissions, and extend the lifespan of existing infrastructure globally.