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Technology for a better society

JP-NO Energy Science Week, Tokyo, 2015-05-28

Smart cities and industries, session

1

Conversion of surplus heat in industry

Petter Nekså [email protected]

Chief Research Scientist

SINTEF Energy Research

Also,

Adjunct Professor at NTNU,

Dept of Energy and process engineering

Visiting Professor at Doshisha University,

Energy Conversion Research Center, Kyoto

mailto:[email protected]


Outline

2

Surplus Energy Utilisation, Technology areas focussed

How we work

Ways to utilise

Basic considerations

Application and project examples

New opportunities HeatUp

HighEff

Conclusions


Surplus Energy Utilisation, Technology areas focussed

3 3

Surplus heat

Conversion to power

Energy exchange to other processes

Heat for CCS

Energy exchange in clusters

Oppvarming i nærområdet

District heating Heat upgrade

Technology for a better society 4

How do we work?

Theory

Experimental Modelling and simulation

University NTNU

Contract research SINTEF

Gemini Center Energy Processes


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Core activities for utilisation of surplus heat – capture and utilisation of surplus heat

SINTEF Energy Resarch

Surplus energy

Heat capture

Heat exchange

Surplus heat utilisation

Direct use Conversion to electrical power

Heat pumping to higher temp

level


Symbiosis: experimental and modelling and simulation

Simulation

models

Dynamic behaviour (Modelica)

Cycle analysis &

optimi-zation

(CSIM)

Fluid thermo-physical

properties

Compo-nent

design (FlexHX)

Experimental activity

Operation and control

Cycle perfor-mance

Practical chall-enges

Com-ponent design

Validation of models Basis for new correlations

Novel cycles New/improved comp. designs Optimized operation

Technology for a better society 7 7 7

• Large amounts of surplus heat available e.g. in metal industry (50-65%) and other industries

• Often no or few possibilities for direct use since • In Norway, industry is located remote in small communities,

often close to hydropower plants • Poor coherence in availability and need

• Possibilities for utilisation of heat most often:

• in industry clusters • power production • high temperature heat pumping

Surplus heat utilisation


BASIC CONSIDERATIONS

8


Power production from a limited sensible heat source

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• Importance of the temperature level and capturing at high temp • Utilisation of a limited sensible heat source results in a gliding

temperature of the source when utilised • Ideally we would like to take maximum advantage in utilisation

of the heat source – > cool the heat source down to ambient temperature

• Constraints/barriers often limit the utilisation – E.g minimum temperature before corrosive components start condensing

T

Tamb

S

Total energy = Tmean ∆S = constant Available energy = (Tmean - Tamb)∆S

0 50 100 150 200 250 3000

0.1

0.2

0.3

0.4

0.5

0.6

heat source temperature (C)

effc

icie

ncy

Tlow=20C

isothermal carnot efficiencygliding temperature carnot efficiency (Cp=cte)

,

. ln1

highlow

lowthermal gliding

high low

TT

TT T

η

= −−

high lowthermal

high

T TT

η−

=

Constant Gliding Partly utilisation


Adaptation of power cycle of the heat engine to heat source and sink

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• Low grade energy source: – Theoritical (Carnot) efficiency is

limited – Net work is proportional to the

source temperature drop Wnet = ƞthermal ṁ cp ∆T

• The pinch problem : – Limits temperature for heat

absorption – Limits the temperature drop of

the source

Position in the heat exchanger

Ttem

pera

ture

Heat source

Working fluid

Pinch

⇒ Tout of the source after utilisation should be low ⇒ Tout of working fluid after heat absorption should be high


Application and project examples

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EFFORT project example:

Power Production from Surplus Heat Sources

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Low temperature compressed gas (150'C)

• High pressure -> compact HX

• Rankine Cycle

• Subcritical hydrocarbon

• Transcritical CO2 or hydrocarbon

High temperature gas turbine exhaust gas (550'C) • Compact bottoming Rankine Cycles

• Transcritical CO2 • Steam, once though boilers • Hydrocarbons


Combined cycle GT+BC Bottoming cycle for a Gas turbine

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Gas turbine Bottoming cycle


Combined cycle GT+BC Bottoming cycle for a Gas turbine

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Plan type Simple cycle Combined cycle single stage

Combined cycle dual stage

Gas Turbine GE LM2500+G4 GE LM2500+G4 GE LM2500+G4 Net plant power output [MWe] 32.2 41.1 42.0 GT gross power output [MWe] 32.5 32.1 32.1 CO2 turbine shaft power [MW] - 13.0 14.2 CO2 pump shaft power [MW] - 2.7 2.9 CO2 BC gross power output [MWe] - 9.5 10.4 Plant efficiency [%] 38.6 48.9 50.0 Exhaust mass flow [kg/s] 89.9 89.9 89.9 Exhaust Temperature after WHRU [°C] 528 170 126

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Design point – Main results CO2 as working fluid

• 28-30 % increase in net power output

• 10-11.5 %-points increase in total efficiency

• About 1 MWe difference between single and dual stage


Heat recovery with power conversion in Aluminium Aluminium electrolysis, Årdal I

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Main observations Energy in cell exhaust 480 GWh/year Low temperature, around120 °C Energy by radiation/convection about same


Heat recovery with power conversion in Aluminium

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How to capture all heat? How to capture at highest possible temperature?

Temperature in cell bath about 900'C May process modifications give higher temperature heat available Is it possible to do it cost efficient in competition with other investments

Technology for a better society 17

ITRI

Partners

http://www.jbtfoodtech.com/

http://www.kth.se/?l=en_UK


Energy efficiency Heat and cold accumulation

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• CO2 for low temperature cold accumulation

Ref: Nordtvedt et al 2011

Ref: Niu et al 2010

Ref: Hafner et al 2011


Energy efficiency Refrigeration, ac and heat pumps

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• Modelling and simulation

• Stationary and dynamic

• Components

• Systems

Dynamic model for freezing tunnel

and refrigeration system Reference: Andresen et al 2011

System sim with detailed

component models, stationary Reference: Skaugen et al 2010

Evaporator

Low Pressure Receiver

Internal HX

Compressor

Gas cooler

1

2 3 4

5

6

ph

p


Example: CFD simulation on performance of GSHX

3-D model

CFD simulation

D tube

D borehole

Borehole wall

Backfill grout in the borehole

Grout

Outlet of fluid

Inlet of fluid

Q

Influence factors

HX length (m);

Fluid inlet temperature (K); Fluid inlet velocity (m/s)

Initial soil temperature (K); Soil types for different areas

Backfill material (Water, air, different soils)

Ref: Hu et al 2012 (CREATIV project PostDoc)


Energy efficiency improvement Surplus heat utilisation in industry clusters (ROMA and CREATIV)

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• Modelling and simulation

• Dependencies • Long term

scenarios

Ambient heat

Biomass

Windpower

Hydropower Waste

Gas / Oil

Hydrogen

Solar

Ref: Nordtvedt et al 2011


Energy efficiency improvement possibilities

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• Process analysis • Modelling and simulation (e.g. EFFORT, CREATIV, ROMA, FUME) • Development of tools, stationary and transient (e.g. EFFORT, CREATIV, ROMA, FUME)

• Surplus heat utilisation • Heat to power (e.g. ROMA, CREATIV , EFFORT) • Heat to other purposes, e.g. cold production (e.g. CREATIV) • CCS (e.g. BIGCCS, DECARBIt, Nordiccs…)

• Industry clusters (e.g. ROMA and CREATIV)

• Heat capture and refining • Concepts for heat capture and its equipment (e.g. HALUP, CREATIV, ROMA, EFFORT) e.g. from dirty

gases

• Equipment efficiency improvements • Heating and cooling equipment (e.g. CREATIV, HALUP)

• Heat and cold accumulation • Storage for peak shaving (e.g. CREATIV)

• Process improvement • Process modification for heat refining (increased temperatures) (e.g. ROMA and HALUP) • Development of new process layouts (e.g. IDEALHY, DECARBit and CREATIV)


New opportunities

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Utilisation of surplus heat from industrial processes

Surplus heat from 30°C to 50°C and higher Heat pumping for delivery at 80°C to 180°C (250°C)

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Focus of HeatUP:

Solution depending on temperature requirements and energy demand of the industrial process


Focus on efficient energy use and how to meet the increasing energy demand in an environmentally benign way

• Statoil Oil and gas industry

• Statkraft Varme District heating

• Hydro Aluminium Aluminium, producer and supplier of al-products

• Vedde/TripleNine fish oil- and forage producer

• Mars Petcare producer of forage, chocolates and beverages

• TINE SA producer of diary products

Represents three of the largest industry sectors in Norway:

Oil and gas

Metal production

Food technology

Vendors

Hybrid Energy, Cadio AS, Epcon Evaporation Technology

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HeatUp: Industry partners

Centre for Environmentally Friendly Energy Research

Centre for Energy Efficient and Competitive Industry with Low Environmental Impact

HighEFF

Center leader: Anne Karin T Hemmingsen version:

2015-05-27

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FOCUS AREAS

Smart thermal grids, energy storage and

integration with renewables

Process framework, cost efficient

components and unit processes

Optimal surplus heat- capture,

conversion and utilization

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Conclusion

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• There are a lot of important challenges to be addressed

• Energy efficiency and utilisation of surplus heat is important

Thank you very much!

conversion of surplus heat in industryinjapan.no/energy2015-day2/files/2015/06/06_conversion... ·...

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