Dissertations / Theses on the topic 'Industrial waste heat'

Abstract. Industry produces large amounts of waste heat, which is not utilized. This thermal energy could be used for an example in residential heating in the colder seasons of the year, when the heating demand is larger. Using heat storage technologies, waste heat could be stored for later use. In this thesis, heat storage technologies were reviewed. The main technologies reviewed for heat storages were sensible heat storages and latent heat storages. In addition, chemical heat storage is a promising technology, which is currently in the research phase. Furthermore, some heat storage pilot projects were reviewed reviewed as well. The heat demand for space heating, heat production and industrial waste heat production in Finland are also reviewed. Heat demand for space heating in 2017 was some 45,35 GTWh in total, and 13,88 GWh of that was district heating. The production of district heat in 2017 was 38,29 TWh in total. At the same time, annual industrial waste heat production in Finland was estimated to be 54 TWh. Although of this, only 4 TWh was estimated to be commercially usable; notwithstanding, it can be concluded that utilizing industrial waste heat for space heating could lead to substantial emission reductions.Lämmön varastointiteknologiat : teollisuuden hukkalämmön hyödyntäminen asuintilojen lämmitykseen. Tiivistelmä. Teollisuus tuottaa paljon hukkalämpöä, jota ei hyödytetä. Tätä energiaa voitaisiin käyttää esimerkiksi kaukolämpöverkossa vuoden kylmempinä aikoina, kun lämmityksen tarve on suurempi. Lämpövarastojen avulla tuotettu hukkalämpö voitaisiin varastoida myöhempää käyttöä varten, mikäli lämmityksen tarve ei ole hukkalämmön syntyhetkellä korkea. Tämän työn tavoitteena oli etsiä tietoa lämmönvarastointi teknologioista, jotka ovat sopivia teollisen hukkalämmön varastointiin. Pääasialliset lämpövarastoteknologiat ovat havaittavan lämmön sekä sitoutuneen lämmön varastointiteknologiat. Lisäksi myös kemiallinen lämmönvarastointi on lupaava teknologia, mikä on vielä tutkimusvaiheessa. Työssä käytiin läpi myös projekteja, jotka liittyvät lämmön varastoinnin ja hyötykäytön pilotteihin ja mitoitukseen. Työssä myös selvitettiin myös asuintilojen lämmitystarve Suomessa, lämmityksen tuotantomäärät ja -tavat, sekä teollisuuden hukkalämmön tuotannon määrä. Talojen lämmöntarve Suomessa vuonna 2017 oli noin 45,35 TWh josta 13,4 TWh oli kaukolämpöä. Kaukolämpöä tuotettiin Suomessa vuonna 2017 38,29 TWh. Samalla teollisuuden hukkalämmön arvioitiin syntyvän vuosittain 54 TWh, josta 4 TWh olisi taloudellisesti kannattavasti käytettävissä. Taloudellisesti käytettävissä olevaa hukkalämpöä verrattaessa kaukolämmöntarpeeseen nähtiin, että hukkalämmön käytölle kaukolämmössä olisi potentiaalia. Jos teollisuuden hukkalämpöä pystyttäisiin käyttää tehokkaasti tilojen lämmityksessä, voitaisiin saavuttaa huomattavia päästövähennyksiä.

One of the major challenges of this decade is developing more sustainable energy systems that contribute to environmental concern, especially climate change mitigation. Extending the operating conditions of the heat pump technology to higher temperatures will allow decarbonising the industrial sector from two slopes: recovering heat from waste heat sources that currently is being rejected to the ambient and produce heat at the required industrial thermal levels that become useful for the industrial processes. Both challenges will make possible reduce the equivalent CO2 emissions of the industrial sector and operate at high temperatures that conventional heat pumps. This thesis deals with the development of high temperature heat pumps through a comprehensive theoretical and experimental analysis to overcome different technology challenge: architecture, refrigerants, experimental prototype, advanced applications and system integration, providing new knowledge that represents a step forward in high temperature heat pump technology.
Uno de los mayores desafíos de esta década recae en el desarrollo de sistemas energéticos más sostenibles que contribuyan a la preocupación medioambiental, especialmente la mitigación del cambio climático. Extender las condiciones de funcionamiento de la tecnología de bomba de calor a temperaturas más elevadas permitirá descarbonizar el sector industrial desde dos vertientes: recuperando calor de fuentes de calor residual, actualmente disipado al ambiente y producir calor a los niveles térmicos requeridos, útiles para los procesos industriales, reduciendo así las emisiones de CO2 equivalentes del sector industrial y contribuyendo al desarrollo sostenible. Esta tesis pretende abordar el desarrollo de bombas de calor de alta temperatura a través de un análisis teórico y experimental, para abordar diferentes desafíos tecnológicos: arquitectura, refrigerantes, prototipo experimental, aplicaciones avanzadas e integración de sistemas, generando nuevos conocimientos que representan un paso adelante en la tecnología de bombas de calor de alta temperatura.
Programa de Doctorat en Tecnologies Industrials i Materials

En l’actual context energètic, l'ús de la calor residual industrial (CRI) representa una oportunitat atractiva de substituir el consum d'energia primària per un mitjà amb baix nivell d'emissions i baix cost. Aquesta calor es pot recuperar i reutilitzar en altres processos, ser transformada en electricitat o calor.Tot i el seu prometedor potencial, aquest CRI no s’utilitza. L'objectiu d'aquesta tesi doctoral és el de superar algunes de les barreres tecnològiques i d'informació actuals que dificulten l’ús d’aquesta fot d’energia. En primer lloc, s’ha identificat el potencial mundial actual de CRI a escala de. En segon lloc, es va generar noves avaluacions d’estimació del potencial de CRI: a la indústria de la manufactura espanyola i en la indústria de minerals no metàl•lics Europea. Finalment, es va tractar la recuperació i reutilització d'aquesta calor mitjançant l’emmagatzematge d’energia tèrmica i es va avaluar exhaustivament els casos pràctics on aquesta tecnologia ha estat implementada.
En el actual contexto energético, el uso del calor residual industrial (CRI) representa una oportunidad atractiva de sustituir el consumo de energía primaria por un medio de bajo nivel de emisiones y de bajo coste. Este calor se puede recuperar y reutilizar en otros procesos, ser transformado en electricidad o en calor. A pesar de su prometedor potencial, este CRI está actualmente en desuso. El objetivo de esta tesis doctoral es el de superar algunas de las barreras tecnológicas y de información que existen actualmente en la utilización de esta fuente de energía. En primer lugar, se ha identificado el potencial mundial actual de CRI a escala de país. En segundo lugar, se generaron nuevas evaluaciones de estimación del potencial de CRI: en la industria de la manufactura española y en la industria de minerales no metálicos Europea. Finalmente, se trató la recuperación y reutilización de este calor mediante almacenamiento de energía térmica y se evaluó exhaustivamente los casos prácticos donde esta tecnología ha sido implementada.
In the current energy context, the use of industrial waste heat (IWH) provides an attractive opportunity to substitute primary energy consumption by a low-emission and low-cost energy carrier. Despite its potential, IWH is largely untapped. This heat can be recovered and reused in other processes, transformed into electricity or heat. The aim of this PhD is to overcome some of the current technological and information barriers and to provide the literature and the researchers with more knowledge of the topic and supporting its widespread development. First, current IWH potential worldwide at country scale was identified. Second, new assessments to estimate the regional IWH potential were generated: in the Spanish manufacture industry as well as in the European non-metallic mineral industry. Finally, its reuse by means of thermal energy storage (TES) was analysed and an exhaustive research of current case studies was performed.

This thesis aims to examine energy demand within UK industry and assess the improvement potential available through efficiency measures. The techniques employed throughout the work have been mainly engineering based, drawing on thermodynamics. Alongside this approach, an assessment of drivers and barriers to the technical potential was undertaken. Data availability was a key challenge in the current work. The variety in energy uses meant the use of publically available datasets was limited. A database was constructed utilising site level emissions data, and employed a subsector disaggregation that facilitated energy analysis. The database was used for an analysis of waste heat recovery options. Opportunities were identified in low temperature recovery, heat-ta-power technology, and the transport of heat. Each of these options would require further research and support to be fully realised. It was found that splitting the industrial sector into an energy-intensive and non-energy- intensive subsector, where the grouping was based on the drivers to energy efficiency, allowed generalisations to be made regarding future improvement potential. Based on analysis of past trends, it was found that the energy-intensive subsector has limited potential for further efficiency gains through currently used processes. To make significant improvements radical changes in current processes will be required. A study of the energy-intensive Cement subsector concurred with these findings. Future efficiency improvements in this subsector are likely limited without a shift to alternative cement production. The non-energy-intensive subsector was thought to have relatively greater improvement potential through existing processes. The analysis of these processes is limited by lack of data however. An analysis of the non-energy-intensive Food and drink subsector therefore focussed on improvements in supplying low temperature heat, rather than the efficiency of specific processes. Opportunities through improving steam systems, increasing combined heat-and-power use, and the adoption of heat pumps were found to offer similar improvement potentials.

This thesis focuses on the use of small-scale Organic Rankine Cycles (ORC) to produce electricity from low-grade waste heat recovery of industrial processes. In particular, a thermo-economic (combination of thermodynamic and economic) optimization is conducted to achieve more cost-effective systems and, thus, to contribute to the ORC adoption in practical applications. As a novelty, this investigation is based on an experimental application case, which allows developing a comprehensive model of the system and its subsequent validation from actual data. Thereby, more realistic results are reached, which underline the most relevant topics to pay attention to improve the economic feasibility of new projects.
Esta tesis se centra en el uso de sistemas de pequeña escala basados en el ciclo Rankine orgánico (ORC por las siglas en ingles) para la producción de electricidad a partir de la recuperación de calor residual de baja temperatura en procesos industriales. En concreto, se lleva a cabo una optimización termoeconómica (combinación entre termodinámica y económica) como método para mejorar la rentabilidad de los proyectos y, de esta forma, favorecer el uso de los sistemas ORC en aplicaciones prácticas. Como novedad, la investigación se lleva a cabo en torno a un caso experimental de aplicación, lo que permite desarrollar un modelo íntegro del sistema y posteriormente validarlo con datos reales. De este modo, se alcanzan resultados más realistas que ponen de relieve los aspectos clave para mejorar la viabilidad económica de nuevos proyectos.

The report comprises two separate parts:

• part 1:  Temperature needs for district heating in the paint shop for axles in building 210
• part 2:  Energy and low temperature waste heat solutions in heating and cooling systems for   building 64 with surroundings

The paint shop for axles in part 1 has air quality requirements in places for coating of axles. Toachieve desired air properties there are different process ventilation systems, which consist ofventilation coils for heating and cooling, plus air humidifier. The ventilations coils for heating usedistrict heating. Today the ventilation coils use water of 100°C to achieve necessary air demands inthe coating boxes. This part of the report investigates whether the existing system would achievethe air requirements with a water temperature of 75°C instead of 100°C in the ventilation coilsduring the coldest parts of the year. The conclusion is that it is not possible; the existing system isadjusted for a water temperature of 100°C to achieve the air requirements. To use a watertemperature of 75°C, more or major ventilation coils are needed.

The focus of the report is at part 2. In this part, possibilities for low temperature waste heatsolutions are investigated. Those partly aim at specific local solutions for building 64 withsurroundings and on the other part of general waste heat solutions for new buildings andreconstructions in the future. To make these parts possible, the systems for heating and cooling inbuilding 64 have been identified. During this identification, potential savings that are not of wasteheat character have also been observed.

The most profitable saving concerns the control of temperature for the inner hardening vat. It isthe hardening vat for gas carburizing oven SV16838 that has been studied in this report. Today thetemperature of the hardening vat is controlled very ineffective. The conclusion is that a betteradjustment of the controller would save 180 000 SEK/year with a pay off time around two months.Worth mentioning (SV16838 included), is that there are at least five similar gas carburizing ovens atthe Scania area in Södertälje.

A pinch analysis has also been done for building 64, with it’s primarily conclusion that the groundheating is violating the pinch rules during long periods of the year. To remedy the ground heatingwill only need a different control and will lead to a saving between 20 000 – 75 000 SEK/year. Tomore accurate determine the saving, an investigation of the ground heating during winter time isneeded. Another conclusion concerning the pinch analysis is that the method for a real scenariorather shows the potential of the system than gives you an optimal solution possible to implement.More actions are to use the exhaustions of the endo gas generators and that the washing andrinsing systems if possible not should be heated with electricity. The exhaustions from the endo gasgenerators have a very high temperature, more then 300°C. If these, instead of hot water boilers,could warm the closely located water for the LPG (liquefied petroleum gas) evaporation, 125 000SEK/year can be saved. Today the hot water boilers are heated with electricity. If the washing andrinsing systems existing electricity heating instead can be heated with secondary heat (˜ districtheating), a save of 500 000 SEK/year is possible.

For waste heat solutions there are a few different approaches. Close to building 64, the largestpotential to use waste heat is in building 62 and 75, where air heaters are assessed with the largestpotential. In difference to other investigated buildings, building 210 has the possibility to use wasteheat even during the summer. This building is located 1 km from building 64. To use waste water inbuilding 210, a complex net of waste heating will be required where several buildings with asurplus of waste heat can be connected. A net like this has calculated pipe costs of 5, 2 million SEK.The saving for the use of waste heat only in building 210 will be around 1,4 million SEK/year. Thissave corresponds to the air handling systems that occur in part 1.

District heating has a long standing tradition in Sweden and today it is the most common way of producing and transporting heat. A District heating system (DH system) is divided into three parts: a production facility, distribution network (DH network) and one more heat stations. The heat produced in the facilities is distributed to the customers via a heat transfer medium, usually water (DH water), in piping networks that make up the DH network. The heat is transferred to the customers via the heat exchanger at which point they can use it as heated tap water or for heating purposes. The DH networks are often constructed in steel as it is cheap and a relatively resistant material. However it has the disadvantages of corrosion and expansions when it is exposed high temperatures which lead to damages in the DH network resulting in loss of the DH water, this is an unavoidable occurrence in any DH network. This results in addition of pollutants by leakages into the DH network or with the water that is used to compensate for the losses. The pollutants cause further corrosion, leading to metal contamination, and more damages on the DH network meaning there is a continuous degradation. Therefore various treatments are used to clean and ascertain an acceptable chemical environment in the DH systems. These treatments are effective but not at a level which is required so many chemicals are used to enhance the treatment of the water. Some of these are known to be toxic to humans and water ecosystems. As leakages are abundant and often end up in the WWTPs of the concerned municipality, which often have troubles with disturbances of the biological treatment, it was decided that an assessment of the toxic effects that DH water pose on activated sludge was to be investigated. This was done by testing water from two DH networks, Växjö and Kalmar, on the same activated sludge obtained from Tegelviken WWTP in Kalmar. A respirometric bioassay approach established by the Organization for Economic Co-operation and Development (OECD), OECD standard 209; OECD Guidelines for the Testing of Chemicals was used with changes made to exposure and measuring time as this decrease the risk of misinterpretation of the results. A dilution series using different concentrations (6.25%, 25% and 100%) of DH water was tested and compered to a blank control samples containing only activated sludge. Assessment of toxicity on total oxidation, oxidation carbon and oxidation of nitrogen was made. To get some idea of what might cause toxic effect samples of the waters was sent to outside laboratories for analyses of metals. The result from the bioassay and metal analysis was used to formulate risk factors associated with a DH water spill and exposure to WWTPs. It was found that both DH waters have a significant inhibition on nitrification in WWTPs. The DH water from Kalmar exhibited similar toxicity dynamics, roughly 20% inhibition, despite large differences in concentration. The DH water from Växjö showed a negative correlation between an increase in concentration of DH water and toxicity, 74% for the lowest concentration and 11% for the highest. The metal analysis concluded that there was no abundance of metal contamination which led to the inference that toxicity is probably caused by the chemicals used for treatment. This poses a great risk for the Baltic Ocean as many WWTPs release their treated water directly into water courses with a short detention time before reaching the sea.

The industrial sector accounts for a large share of greenhouse gas emissions. To reduce its negative impact on the environment is crucial in the quest for a sustainable future. In discussions of the industrial sector's impact on the environment guidelines have been highlighted as a tool to assist the industries in their efforts to change the relationship between the consumption of energy and production. This by improving energy efficiency and a shift to the best available technology. During the past 30 years the steel industry has reduced its energy consumption per ton of steel produced by 50 percent. However, due to this dramatic improvement in energy efficiency, it is estimated there is now only room for a marginal further improvement on the basis of existing technology. More innovative solutions are therefore required to further improve energy efficiency and achieve a more sustainable use of resources. In a description of the program Efficiency of Energy Use in Industry – Research and Development undertaken by the Swedish Energy Agency the interaction between industry and society is accentuated as an important factor in energy efficiency efforts. Today, there are already several examples of where the industry and the community work together to achieve a better utilization of resources. The steel industry SSAB EMEA has a manufacturing plant in Borlänge, Sweden, where they have been recycling waste heat from the industrial processes for a long period of time. In 1991 SSAB initiated collaboration with the local energy company regarding recovery of waste heat within the industrial enterprise. Since then, SSAB has contributed to the heating of the residences that are connected to the local district heating network. The present study aims to examine the values that the utilization of waste heat add to the industrial company and the community, and to explore how the use of industrial waste heat can be developed ahead. The examination consists of a case study and is mainly based on qualitative interviews with people from SSAB, the local energy company Borlänge Energi, Borlänge Municipality and the Swedish Energy Agency. Some quantitative data, such as measurements of heat deliveries, have also been used for the analysis. In addition a literature review with a focus on district heating in Sweden, industrial waste heat and instruments in energy and climate policy has been conducted. Through varied system levels the waste heat collaboration in Borlänge has been analyzed from a business, social and sustainable perspective. The result of the case study proves that the waste heat collaboration has added value in all perspectives. Business values that have been identified are reduced purchases of oil, compensation for delivered waste heat, exchange from vapour to in-house district heating within the steel factory site, reduced emissions of carbon dioxide, media attention and an improved brand and that the waste heat collaboration possibly made SSAB a more desirable employer. The use of industrial waste heat for district heating in Borlänge has also generated a range of social benefits, which consist of low operating costs for heat, low price of district heating, good energy mix and better air quality and less acidity. From a sustainability perspective, the waste heat utilization resulted in reduced emissions of carbon dioxide and other air pollutants and has been contributive to a sustainable use of raw materials and energy resources. The results also demonstrate that there are both opportunities and threats to a continued use of industrial waste heat. The opportunities identified are regional district heating networks, which can improve the conditions for effective use of waste heat, district cooling, which may increase the need for waste heat in the summer and in-house electricity production, which can accommodate some of the steel company's electricity need. A few threats to a continued use of waste heat have also been identified, which the first consists of co-generation and waste incineration, which can adversely affect energy companies incentives to enter into and renew agreements on waste heat deliveries since the companies do not want to be afflicted with reduced revenues from sales of electricity and electricity certificates or from the reception of waste. Furthermore has changes in energy policy been identified as a threat since for example a new tax on waste heat could worsen the conditions for both continuing and new waste heat collaborations.
Industrisektorn står för en stor andel av växthusgasutsläppen. Att minska dess negativa inverkan på klimatet är således grundläggande i strävan efter ett hållbart samhälle. I diskussioner kring industrisektorns påverkan på miljön har riktlinjer lyfts fram som ett instrument för att bistå industrin i arbetet med att förändra förhållandet mellan konsumtion av energi och produktion. Detta genom en förbättring av energieffektiviteten och en förskjutning till bästa möjliga teknik. Under de senaste 30 åren har stålindustrin reducerat sin energikonsumtion per ton producerat stål med 50 procent. Det sägs dock att dessa dramatiska framsteg i energieffektivitet har lett till att det nu endast finns rum för en marginell fortsatt förbättring förutsatt befintlig teknik. Om så är fallet måste våra vyer vidgas för att vi ska kunna hitta lösningar som innebär större effektivitetsvinster och ett bättre nyttjande av resurser. I en beskrivning av programmet Effektivisering av industrins energianvändning – forskning och utveckling som drivs av Energimyndigheten betonas samspelet mellan industri och samhälle som en viktig faktor i energieffektiviseringsarbetet. Idag finns det redan flera exempel på där industrin och samhället samarbetar för att uppnå ett bättre nyttjande av resurser. I Borlänge har stålföretaget SSAB EMEA en produktionsanläggning där de sedan länge återvinner restenergier från verksamhetens processer. År 1991 ingick SSAB avtal med det lokala energibolaget avseende tillvaratagande av restvärme vid industriföretaget. Sedan dess har SSAB bidragit till uppvärmningen av de bostäder som är anslutna till ortens fjärrvärmenät. Föreliggande studie har som syfte att undersöka vilka värden som tillvaratagandet av restvärmen tillför industriföretaget och samhället, samt ta reda på hur användandet av industriell restvärme kan komma att utvecklas framåt. Undersökningen består av en fallstudie och bygger i huvudsak på kvalitativa intervjuer med personer från SSAB, det lokala energibolaget Borlänge Energi, Borlänge kommun och Energimyndigheten men också på kvantitativ data, såsom mätningar av värmeleveranser. Sedan har även en litteraturstudie genomförts med fokus på fjärrvärme i Sverige, industriell restvärme och styrmedel i energi- och klimatpolitiken. Genom varierade systemnivåer har restvärmesamarbetet i Borlänge analyserats ur företagsekonomiskt, samhällsekonomiskt och hållbart perspektiv. Resultatet av fallstudien visar att restvärmesamarbetet tillfört värden inom samtliga perspektiv. De företagsekonomiska vinster som har identifierats är minskade inköp av olja, ersättning för levererad restvärme, byte från ånga till intern fjärrvärme inom stålföretagets verksområde, minskade utsläpp av koldioxid, medial uppmärksamhet och stärkt varumärke och att restvärmesamarbetet eventuellt gjort SSAB till en mer attraktiv arbetsgivare. Användandet av industriell restvärme som fjärrvärme i Borlänges lokala fjärrvärmenät har även genererat en rad samhällsekonomiska vinster, vilka utgörs av låg driftskostnad för värmeproduktion, lågt pris på fjärrvärme, bra miljömix samt bättre luftkvalitet och mindre försurning. Ur ett hållbarhetsperspektiv har restvärmenyttjandet resulterat i minskade utsläpp av koldioxid och andra luftföroreningar och varit bidragande till ett hållbart nyttjande av råvaror och energiresurser. Resultatet visar också att det finns både möjligheter och hot för ett fortsatt användande av industriell restvärme. De möjligheter som identifierats är regionala fjärrvärmenät, som genom omfattande värmeunderlag kan förbättra förutsättningarna för effektiv användning av restvärmen, fjärrkyla, som kan öka behovet av restvärmen under sommarhalvåret och egen elproduktion, som kan tillgodose en del av industriföretagets elbehov. Sedan har även hot för ett fortsatt användande av restvärme identifierats, vilken den första utgörs av kraftvärme och avfallsförbränning, som kan inverka negativt på energibolags incitament till att ingå och förnya avtal om restvärmeleveranser då bolagen inte vill riskera att drabbas av minskade intäkter från försäljning av el och elcertifikat eller från mottagande av avfall. Även förändringar i energipolitiken har identifierats som ett hot då exempelvis en ny beskattning på restvärme kan försämra förutsättningarna för både fortsatta och nya restvärmesamarbeten.

Les activités industrielles génèrent inévitablement des déchets quelquefois très toxiques. L’évolution des réglementations concernant leur mise en décharge et la pression de l'opinion publique poussent les communautés scientifique et technique à trouver des solutions pour ce problème. Ce travail a exploré les possibilités de la dépollution des déchets industriels métallifères de leurs éléments toxiques (ET) et d'enrichissement des résidus en métaux de valeur (MV). Des traitements thermiques sous atmosphères contrôlées (oxydante, réductrice et chlorurante) sont appliqués sur cinq échantillons provenant d'une usine d'extraction européenne des métaux non-ferreux. L’influence de l'atmosphère gazeuse, de la température, de la durée du traitement sur les taux d'élimination des ET et de concentration des MV est déterminée à l'aide de la DRX, du MEB, de l'analyse chimique, etc. Selon les caractéristiques physico-chimiques des déchets, il était possible d'éliminer en moyenne environ 62 à 99% des ET et de récupérer environ 35 à 100% des MV. Ainsi, il était possible de diminuer les teneurs des ET de 23 à 0,4% et d'accroitre celles des MV de 24 à 46%. Les ET sont séparés de la phase gazeuse par refroidissement alors que les MV sont concentrés dans le résidu du traitement. La réduction des déchets, à des températures 600°C, semble être le traitement le plus efficace pour leur dépollution et leur enrichissement. Certains déchets peuvent être recyclés directement dans les unités industrielles d'extraction des métaux non-ferreux

This report describes the work of developing a specification of requirements for Waste Heat Recovery Units. The main part of the paper describes how the work with the specification of requirements has been performed. One specific question to be answered is:

What are the customer’s demands in case of properties for the Waste Heat Recovery Units and how is that information collected as an order documentation to suit the business area Oil & Gas?

The report begins with a description of the assignment and continues with the aim and background. A theoretical part describes the different areas and methods that have been important during the process. Work on the specification has been carried out on site at the company where interviews of staff and the study of internal documents has been a significant part of the implementation.

The result is delivered to the company in the form of a specification of requirements for the Waste Heat Recovery Unit. This specification fulfills the requirements set initially and is a good starting point for the company to proceed with in contact with subcontractors. The conclusion of the work is that the establishment of a good specification of requirements is really important and that has been obvious during the work and progress of this project. The difficulty lied in getting the right information and to keep it simple and at same time durable.

Au sein des discours accompagnant les volontés de transition énergétique, apparaît de manière grandissante une promotion de circulations d’énergie à des échelles infra-urbaines entre des activités diverses. Des acteurs locaux, nationaux ou transnationaux proposent par exemple de valoriser la chaleur dite « fatale », produite par de multiples activités (industries, data centers, eaux usées …). Parallèlement, on promeut le partage de productions d’énergie décentralisées entre différentes fonctions (résidentiel, tertiaire, commercial …) à des échelles allant de l’îlot au quartier. En somme, des formes de connexion entre activités urbaines pour échanger de l’énergie sont promues et les exemples de mise en œuvre se multiplient.Cette thèse propose de saisir ces connexions comme des nouvelles formes de réseaux urbains, qui se substituent ou se superposent à un modèle de grand réseau centralisé plus que centenaire, fondé sur l’efficacité technico-économique, la solidarisation du territoire et la croissance des consommations. Elle vise à comprendre ce que change l’émergence de ces circulations locales à la co-construction de la ville et des réseaux d’énergie.Pour saisir ces transformations, la thèse combine les apports de deux ensembles de travaux. D’un côté, les recherches urbaines et sociotechniques sur les réseaux permettent de saisir les reconfigurations de ces infrastructures. D’un autre, le champ de l’écologie industrielle et territoriale analyse les dynamiques qui mènent à des échanges de flux matériels entre activités humaines. La combinaison de leurs résultats permet ainsi de saisir l’objet considéré dans ses dimensions sociale, technique et métabolique, c’est-à-dire dans une perspective sociomatérielle.L’analyse se fonde principalement sur trois études de cas dont on s’attache à comprendre l’émergence, le fonctionnement et l’évolution : l’approvisionnement du réseau de chaleur de Dunkerque par une source de chaleur industrielle, la récupération de chaleur sur un data center pour approvisionner un quartier de Marne-la-Vallée et la mutualisation des productions d’énergie dans le quartier de La Confluence à Lyon. Plus largement, un regard est porté sur les reconfigurations concrètes ou proposées de l’organisation de la chaîne d’approvisionnement énergétique à la ville.Les résultats de la thèse sont de trois ordres. En premier lieu, ces mises en réseau ne sont plus motivées par la seule efficacité technico-économique de la forme réticulaire pour l’approvisionnement du territoire. Les intérêts des différents acteurs impliqués ont tous à voir avec un objectif d’optimisation de l’usage des flux : on passe ainsi d’une recherche d’efficacité technico-économique à celle d’une efficacité métabolique. En second lieu, les réseaux qui émergent de ces échanges sont instables, tout particulièrement en raison des incertitudes quant à l’évolution à court et à long terme des flux disponibles. Ainsi, ils ne reproduisent pas l’effet solidarisant permis par la stabilité des grands réseaux conventionnels. Enfin, face à ces instabilités, les acteurs proposent des évolutions qui visent à réduire les dépendances à des flux incertains. Ces évolutions ont pour caractéristique de s’appuyer sur une croissance du réseau qui ne suit plus un objectif d’universalisation. Au contraire, une forte sélection spatiale de l’extension du réseau est opérée, en fonction de la matérialité des flux perçue par les acteurs. Plutôt que d’engendrer de nouvelles consommations dans une logique d’offre, il s’agit ainsi d’intégrer de nouveaux flux déjà présents sur le territoire.En somme, la thèse montre un certain « tournant métabolique » dans le processus de mise en réseau de la ville par l’énergie. Alors que l’extension des infrastructures est pendant longtemps restée au centre des problématiques de construction des réseaux, les flux produits et consommés qui préexistent sur le territoire peuvent à présent être la motivation première de la création de connexions
Within the framework of the ongoing energy transition objectives, energy circulations at the infra-urban level are increasingly promoted. For instance, local, national and transnational stakeholders suggest the reuse of heat currently being wasted by diverse human activities (industries, data centres, wastewaters …). Alternatively, distributed energy sharing between different urban functions (residential, services, retail …) at the urban block or district scale is promoted. In short, several forms of connections through energy exchange between urban activities are encouraged and examples of those are multiplying.The thesis offers to capture those connections as new forms of urban networks that supersede or overlap a century-old network model based on techno-economic efficiency, socio-economic and socio-spatial solidarity and consumptions growth. It aims at understanding what these local circulations change to the co-construction of cities and energy networks.To do so, the approach combines the results of two different strands of work. On the one side, urban and sociotechnical studies of networked infrastructures allow to understand the reconfigurations of those systems. On the other side, industrial ecology works analyse the dynamics that lead to material circulations between human activities. The articulation of their results makes it possible to grasp the considered object in its social, technical and metabolic dimensions, that is, in a sociomaterial perspective.The analysis is mainly based on three French case studies of which the emergence, running and evolution are investigated: industrial waste heat reuse in the heat network of the city of Dunkirk, heat extraction from a data center to be distributes the in a district of Marne-la-Vallée and energy sharing in the La Confluence district in Lyon. More broadly, suggested or implemented reconfigurations of the organisation of energy provision are reviewed.The results of the study are threefold. First, these new forms of urban network are not solely motivated by techno-economic efficiency. The interests of the stakeholders all come into alignment with an objective of optimization of energy flows uses: from techno-economic efficiency, the goal becomes metabolic efficiency. Second, the networks formed by those circulations are unstable, in particular because of the uncertainties that regard short and long term availability of energy flows. Hence, they do not reproduce the solidarities that emerge from conventional large and stable networks. Third, to reduce those instabilities, actors suggest evolutions that aim at reducing their dependencies on uncertain flows. These evolutions all result in the growth of the network, but do not follow an objective of universalisation. On the contrary, an important spatial selection is operated, according to the perceived materiality of flows by actors. Instead of leading to new consumptions in a supply rationale, the logic becomes one of existing flows integration.To sum up, the thesis shows a “metabolic turn” in the process of networking the urban through energy circulations. While infrastructures extension has long been at the centre of networks construction, pre-existing produced and consumed flows can now become the primary motivation of building connections

A l'heure actuelle, l'industrie représente environ le tiers de la consommation énergétique et des émissions de CO2. Des opportunités substantielles existent pour faire face aux enjeux environnementaux et économiques, passant par l'efficacité énergétique en général et l'utilisation de l'énergie, en particulier dans les parcs industriels. Les Systèmes à Energie Distribuée (SED) correspondent en ce sens à une solution courante et prometteuse. Nous avons donc entrepris une démarche d'approche globale de site, incluant l'agrégation de l'ensemble des variables énergétiques, économiques, environnementales et managériales influentes dans une installation de ce type. Une mise en application sur une installation pilote et sa validation ont permis d'identifier les verrous scientifiques et techniques et de mesurer pertinence et efficacité des éléments et modes opératoires des systèmes en mode stationnaire. Cette étude offre une méthode d'utilisation coopérative des indicateurs des domaines impactés et ouvre également des perspectives sur des développements en mode dynamique à des fins d'aide à la conduite optimale
Nowadays, industry accounts for about one third of energy consumption and CO2 emissions. Substantial opportunities exist to address environmental and economic challenges, including energy efficiency in general and the use of energy, especially in industrial parks. Distributed Energy Systems (DES) correspond in this sense to a common and promising solution. We have therefore undertaken a global site approach, including the aggregation of all influential energy, economic, environmental and managerial variables in an installation of this type. Implementation on a pilot plant and its validation have made it possible to identify the scientific and technical locks and to measure the relevance and efficiency of the elements and stationary operating modes of the systems. This study offers a method of cooperative use of the indicators of impacted domains and also opens perspectives on developments in dynamic mode for the purposes of optimum driving assistance

In order to keep a high level and to stay competitive in the world market in the future, it is important for the Swedish steel industry to improve their efficiencies continuously and to reduce the energy consumption. In order to realize these goals, the Swedish steel association Jernkotoret was found and by their initiative Triple Steelix was found in 2006 in Berglanden, a significant area for the steel industry. In 2009, the Clean Production Centre was found in Hofors in order to build a cluster of local steel manufacturers, factories and companies. One of those companies is Gästrike Härdverkstad, a small steal heat treatment industry with six employees and about 700.000 tons treated materials every year. The aim for this thesis is to suggest solutions for recovering waste heat and lowering the total energy consumption in furnaces for heat treatment in the case of Gästrike Härdverkstad. Some limitations were necessary to complete the analysis and to come to conclusions. The yearly treated material and energy prices were assumed to be constant and the yearly power consumption was estimated by an extrapolation of a one to five days measurement. Gästrike Härdverkstad is located in Uhrfors, the southern part of Åshammar, a village with 727 inhabitants. There are not any buildings with a possibility to supply heat and there is no district heating in the surroundings. The company has a power consumption of 1.40 GWh/year, of which 65.7% is consumed by the 12 main furnaces. The rest is used by eight seldom used furnaces, devices and auxiliary machines of the support process like fans, pumps, compressor, office heating, and some other. The efficiencies of the main furnaces are between 10% and 20%.The estimated energy consumption of the space heating is about 27 MWh/year, which completely can be covered by the material coolant and the combustion heat of the exhaust gases from the hardening furnaces. Since there are 10 different types of furnaces with different duties and efficiencies, the preheating furnace was taken as an example and compared with a new furnace. According to the needs of Gästrike Härdverkstad, the furnace VAW 60/100-650°C from the company Vötsch was chosen at the cost of 248,827 SEK. The payback time depends on the efficiency. With an efficiency of 40% the payback time would be about 13 years, see Figure 20. After the annealing and ageing, the finished products are cooled down in the building hall by the ambient air. In future, the possibility of preheating the material with the heat of the finished products should be considered. With an efficiency of 30.87%, one preheating furnace could bereplaced, and taken a payback time of 5 years into account; the price of the construction would be allowed to be up to 253,200 SEK.

The industrial sector accounts for approximately 30% of the global total energy consumption and up to 50% of it is lost as waste heat. Recovering that waste heat from industries and utilizing it as an energy source is a sustainable way of generating electricity. Supercritical CO2 (sCO2) cycles can be integrated with various heat sources including waste heat. Current literature primarily focuses on the cycle’s performance without investigating the economics of the system. This is mainly due to the lack of reliable cost estimates for the cycle components. Recently developed cost scaling models have enabled performing more accurate techno-economic studies on these systems. This enables a shift in focus from plant efficiency to economics as a driver for commercialization of sCO2 technology. This work aims to develop a techno-economic model for these waste-heat-to-power systems. Based on the literature, waste heat from different industries is calculated, showing that the four industries with the greatest potential for waste heat recovery are cement, iron and steel, aluminum and gas compressor stations. Six different sCO2 cycle configurations were developed and simulated for these four industries. The techno-economic model optimizes for the highest Net Present Value (NPV) using an Artificial Bee Colony algorithm. The optimization variables are the pressure levels, split ratios, recuperators effectiveness, condenser temperature and the turbine inlet temperature limited by the heat source. The results show a vast potential for industries to cut down costs using this system. Out of the four industries modeled, a waste heat recovery system in an iron and steel factory yielded the highest NPV. Results show that the integration of sCO2 cycle in the cement industry could help reduce their waste heat by 60%, whilst simultaneously enabling them to cover up to 56% of their electricity demand. The payback period for the four industries varies between 6 to 9 years. Furthermore, simple recuperated sCO2 cycles with preheating are more economical than recompression cycles. Even though recompression cycles have higher thermal efficiency, they are limited by the temperature glide in the waste heat exchanger. This analysis could help investors and engineers take more informed decisions to increase the efficiency and economic return on investment for sCO2 cycles and heat recovery at industrial sites. To encourage adoption of supercritical CO2 cycles, a demo is needed along with more research for higher temperature applications with special attention to mechanical integrity.
Industrisektorn står för cirka 30% av den globala totala energiförbrukningen och upp till 50% av den går förlorad som spillvärme. Återskapa att spillvärme från industrier och använda det som energikälla är ett hållbart sätt att producera el. Superkritiska CO2 (sCO2) cykler kan integreras med olika värmekällor inklusive spillvärme. Nuvarande litteratur fokuserar främst på cykelens prestanda utan att undersöka systemets ekonomi. Detta beror främst på bristen på tillförlitliga kostnadsberäkningar för cykelkomponenterna. Baserat på nyligen utvecklade kostnadsskalningsmodeller är det möjligt att utföra mer exakta teknikekonomiska studier på dessa system. Detta möjliggör en förskjutning i fokus från cykeleffektivitet till ekonomi som drivkraft för kommersialisering av sCO2 teknologi. Detta arbete syftar till att utveckla en teknisk ekonomisk modell för dessa avfall-värme-till-kraftsystem. Baserat på litteraturen beräknas spillvärme från olika industrier, vilket visar att de fyra industrierna med störst potential för återvinning av spillvärme är cement, järn och stål, aluminium och gaskompressorstationer. Sex olika sCO2 konfigurationer utvecklades och simulerades för dessa fyra industrier. Den teknisk-ekonomiska modellen optimerar för det högsta Net Present Value (NPV) med hjälp av en artificiell bi-kolonialgoritm. Optimeringsvariablerna är pressure levels, delade förhållanden, recuperatorseffektivitet, kondensortemperatur och turbininloppstemperaturen begränsad av värmekällan. Resultaten visar en stor potential för industrier att sänka kostnaderna med detta system. Av de fyra modellerna industrin gav ett återvinningssystem i en järn och stålfabrik den högsta NPV. Resultaten visar att integrationen av sCO2 cykeln i cementindustrin kan bidra till att minska deras spillvärme med 60%, samtidigt som de gör det möjligt för dem att täcka upp till 56% av deras elbehov. Återbetalningsperioden för de fyra branscherna varierar mellan 6 till 9 år. Dessutom är simple recuperated sCO2 cykler med förvärmning mer ekonomiska än recompressioncykler. Trots att recompressioncykler har högre termisk effektivitet, begränsas de av temperaturglidningen i spillvärmeväxlaren. Denna analys kan hjälpa investerare och ingenjörer att fatta mer informerade beslut för att öka effektiviteten och ekonomiska avkastningen på investeringar för sCO2 cykler och värmeåtervinning på industriområden. För att uppmuntra antagandet av superkritiska CO2 cykler krävs en demo tillsammans med mer forskning för högre temperaturapplikationer med särskild uppmärksamhet på mekanisk integritet.

The ever-increasing price of energy, combined with increasingly stringent legislation to reduce greenhouse gas emissions, is driving the UK process industries toward increasing energy efficiency. Significant gains can be made in this sector, as up to 11.4TWh per annum (4% of total energy use) of the UK process industries’ energy consumption is lost as recoverable waste heat. Substantial recovery of this waste heat would have economic benefits of the order of £100s of million/year, and environmental benefits of the order of 100s of thousands of tonnes of carbon dioxide equivalent per year. This thesis describes the development of a knowledge-based system for the selection and preliminary design of equipment for low-grade waste heat recovery in the process industries. The system addresses two of the key barriers to low-grade waste heat recovery in the UK. Firstly, it provides a readily accessible and zero cost tool to replace expensive, time-consuming expert consultancy in the initial stages of waste heat recovery projects, and, secondly, it educates users regarding the range and benefits of novel waste heat recovery technologies. The system requires an input of easy-to-access data from the user. Based on this data, it then selects the most appropriate technologies for waste heat recovery for the case study in question from a database including various types of heat exchanger, vapour compression heat pumps, mechanical vapour recompression and organic Rankine cycles. It also generates a preliminary design including equipment size, efficiency/effectiveness, capital cost, cost savings, payback time and potential reductions in carbon emissions. This provides sufficient information to allow the user to make an educated decision regarding whether or not waste heat recovery is suitable for their needs. The knowledge-base of the system was built using a decision tree method that has been proven to be successful in the building of decision making tools for various engineering applications. The software is programmed using the Java language which allows widespread free dissemination to computers running all common operating systems. The system was tested using case studies based on data from both existing publications and collaborating companies. The results were validated against published results, common modelling software results and the views of expert consultants. Broadly, in terms of equipment specification and cost, the knowledge-based system produced the same results as the other methods. Furthermore, the preliminary designs generated were generally within 5% of the final figures from the other sources. In certain cases, the knowledge-based system suggested alternative technologies that were more viable (economically and/or practically) than those considered by the authors of published case studies. In all cases, system operating time (data input, and processing of results) was of the order of minutes, whereas studies by consultants or the use of existing modelling packages would be significantly more time-consuming (of the order of hours or days). Hence, the system can be used as a rapid optioneering tool for investigation of waste heat recovery technologies, requiring substantially less time than current available methods.

Die Effektivität keramischer Wärmeübertrager kann durch eine feinere Strukturierung der Oberflächen gesteigert werden. Dies kann durch die Integration textiler Urformen anstatt der konventionell im Schlickguss hergestellten gröberen Geometrien erfolgen. Für Strukturierungen in Form von wandgebundenen Halbbögen werden die Ergebnisse umfangreicher experimenteller und numerischer Untersuchungen zu den wärmetechnischen und strömungsmechanischen Eigenschaften vorgestellt. Basierend auf den Erkenntnissen der mittels numerischer Simulation durchgeführten Parameterstudie werden verschiedene Empfehlungen für eine optimierte Anordnung der Halbbögen gegeben, um das Verhältnis von Wärmeübergang zur Druckverlust zu verbessern. Die experimentellen Ergebnisse belegen die Richtigkeit der gewählten Randbedingungen und Vereinfachungen im numerischen Modell. Des Weiteren wurden die Strömungsstrukturen mit laserdiagnostischen Messmethoden umfangreich charakterisiert.

In the metallurgical industry and in refineries and process industries, there is significant amount of waste heat, it is a challenged field to do the research for producing electricity from the energy of waste heat. Traditionallay, Organic Rankine Cycle(ORC)is used for generating electricity from low temperature heat source. Recently researchers are focusing on the supercritical Rankine cycle which uses CO2 as working fluid for which is more environmental friendly working fluid, possilbe reduced size and better utilization of lower temperature heat source.Currently this technology is under development and there is no manufacturing of this technology that can be observed. In this Master's thesis, the overall environmental impacts caused by the CO2 supercritical cycle will be evaluated:1. What are technologies available for producing electricity from low temperature heat?2. What is the electricity that can be generated from a given amount of heat and what type of equipment is needed for this?3. What are the environmental and resource impacts of this type of equipment, based on analyses of similar types of equipment?4. what is the environmental benefit from energy generation comparing with other fossil and renewable electricity production? 5. A brief economic analysis cosidering the waste heat electricity generation

L'augmentation du prix du pétrole ainsi qu'une possible future réglementation des émissions de CO2 encourage les fabricants de véhicules industriels à trouver de nouvelles solutions pour améliorer encore la performance de la chaine cinématique. Dans ce cadre, deux solutions de récupérations d'énergie prometteuses sont très souvent rapportées dans la littérature: le système de récupération d'énergie par cycle de Rankine et le générateur thermoélectrique. Après un rappel des conditions limites du fonctionnement d'un camion long routier, cette thèse démontre tout d’abord la modélisation 0-D et 1-D (logiciels commerciaux utilisés) de ces deux systèmes de récupération d’énergie. Pour le générateur thermoélectrique, des études paramétriques (hauteur de jambe thermoélectrique, prix, puissance électrique produite) sont effectuées se basant principalement sur l'utilisation de deux matériaux prometteurs. Une conception du système Rankine est présentée et modélisée avec le solveur 1-D. Des validations partielles sont réalisées sur les composants (turbine). Ce modèle a ensuite permis d'étudier les transitoires du système ainsi que la charge en réfrigérant et un système de contrôle possible. Cette étude montre que le générateur thermoélectrique n’est pas encore mature pour son utilisation dans un camion long routier. Le système Rankine doit quant à lui être testé sur un camion prototype pour pouvoir véritablement estimer son potentiel final
Fuel price increase as well as future fuel consumption regulations lead truck manufacturers to further enhance the current powertrain. In such a context, two waste heat recovery technologies appear as promising: the Rankine system as well as the thermoelectric generator. After a reminding of truck boundary conditions, this thesis work defines 0-D and 1-D modeling (commercial tool used) for both systems.For the thermoelectric generator , parametric 1-D studies are done on the integration/design (number of thermoelements, price, electrical power) of a thermoelecric generator upstream the existing engine exhaust gas recirculation cooler. Main studies are done with thermoelectric materials but other materials are also considered. A Rankine system design is presented and modeled under a 1-D solver. Preliminary validations are presented. Transient aspects are evaluated to better understand the behavior of the system and its bottlenecks. The amount of refrigerant in the circuit and the control schematic are also addressed.From these studies, it appears that the thermoelectric generator technology is not yet mature for a long haul truck due to the low performance of thermoelectric materials. The Rankine system technology should handle a complete truck prototype testing to estimate its potential

La valorisation des rejets thermiques industriels par leur conversion en énergie mécanique, et éventuellement en électricité, est un moyen de réduire les émissions de gaz à effet de serre et de réduire la consommation énergétique des industries. La présente bourse de thèse est cofinancée par l’Agence De l’Environnement et de la Maitrise de l’Energie (ADEME) dans ce contexte. Le co-financeur de la thèse, Hevatech, est une entreprise qui exploite le brevet d’un nouveau convertisseur de chaleur en électricité appelé Turbosol®. Turbosol® est un bon candidat pour la valorisation de la chaleur fatale industrielle. Le concept en est au stade du développement du prototype et de l’installation de pilotes sur site. L’originalité du cycle de Turbosol® est la détente quasi-isotherme de la vapeur d’eau. Ainsi, le cycle de Turbosol® est proche du cycle de Carnot. La première partie de la thèse porte sur le cycle de Carnot et la faisabilité d’une machine fonctionnant selon le cycle de Carnot. Une machine fonctionnant selon le cycle de Carnot avec de l’eau changeant de phase pendant le chauffage est modélisée, puis optimisée par maximisation de la puissance nette produite. Les variables de l’optimisation sont les températures de vaporisation et de condensation du fluide cyclé, ainsi que la répartition de la surface d’échange entre l’évaporateur et le condenseur. Puis, dans la seconde partie, le modèle de la machine de Carnot est adapté au cas particulier de Turbosol®. Cela permet de simuler le fonctionnement du prototype de Turbosol. L’étude de sensibilité aux variables de commande du modèle a permis d’identifier la température de vaporisation et le débit massique du fluide de travail comme des variables d’optimisation. Ainsi, le convertisseur est optimisé par maximisation de la puissance nette produite et par maximisation du rendement pour un rejet thermique à valoriser donné
To convert the industrial waste heat into mechanical, or electrical energy, is a way to decrease the greenhouse gases emission and the energy consumption. The present PhD thesis is co-financed by the french Environment and Energy Management Agency (ADEME), in this context. The other co-financer, the company Hevatech, exploits the patent of a new heat converter into electricity named Turbosol®. Turbosol® is a good candidate for the industrial waste heat recovery. The concept is currently developed by the study of a prototype and the installation of the prototype on industrial site. The Turbosol® cycle originality is the quasi-isothermal expansion of the water vapor. Consequently, the Turbosol® cycle is close to the Carnot cycle. In the manuscript first part, the possibility of the feasibility of an engine operating according to the Carnot cycle is studied. A Carnot engine with a changing phase working fluid is modeled and optimized by maximization of the net power output. The variables are the optimal vaporization and condensation temperatures, and the optimal allocation of a total thermal transfer area between the condenser and the evaporator. Then, in the second part, the model of the Carnot engine is adapted to the Turbosol® prototype. In the sensitivity analysis, the vaporization temperature and the mass flow rate of the working fluid are identified as optimization variables. So, the Turbosol® converter is optimized by maximization of the net power output and the first law efficiency for a given waste heat fluid to valorize

La valorisation de chaleur fatale industrielle en flux gazeux à haute température peut bénéficier de technologies de stockage thermique thermocline, fonctionnant sur la base d’un matériau de stockage céramique et d’un caloporteur gazeux (air). La diversité des gisements de chaleur fatale et des débouchés potentiels met en évidence la nécessité d’un procédé de stockage versatile et robuste. Ce travail de thèse consiste à accompagner le développement de l’entreprise Eco-Tech Ceram, dont les deux activités sont le développement d’une unité de stockage thermique, et le développement de matériaux céramiques issus de sous-produits industriels destinés à une utilisation dans de telles unités. Concernant l’axe stockage, il s’agit de réaliser une validation expérimentale du concept EcoStock via des essais sur des pilotes représentatifs, notamment concernant la sensibilité des performances au débit de décharge, et à la nature de la ressource thermique disponible en charge (débits et températures d’entrées variables).Concernant l’axe matériau, il s’agit de développer une céramique frittée issue de mâchefer d’incinérateur, et destinée à une utilisation en tant que matériau de garnissage dans un système thermocline à lit en vrac, via une approche expérimentale, dans une démarche d’écologie industrielle et avec l’objectif de diminuer autant que possible les coûts de production et les impacts environnementaux, en calquant les méthodes d’élaboration sur celles des céramiques de batiment (briques et tuiles) dont les capacités industrielles sont pré-existantes. r
The recovery and valorization of high-temperature gaseous waste heat streams can benefit from the development of thermocline thermal energy storage, based on the use of a ceramic material as a solid filler and gases (including air) as heat transfer fluid. The wide diversity of waste heat streams implies developping a versatile and robust system, able to operate in such various conditions.This thesis aims at supporting the development of the company Eco-Tech Ceram, which focuses on developing a compact thermocline air/ceramic thermal storage unit (named EcoStock), and developing ceramics produced from industrial inorganic byproducts, designed to be used as thermal energy storage material. Regarding the « thermal storage » topic, this thesis is focused on the experimental validation of the EcoStock concept, through experimental campaigns on a representative pilot-scale system, especially regarding the influence of operating conditions over performances, and the sensitiviy of the system’s efficiency when discharged at different power level, or charged with low-quality heat streams (varying mass flow rate and inlet temperature during charging phase). Regarding the « ceramic » topic, this thesis is focused on developing a sintered ceramic based on municipal waste incinerator bottom ashes compatible with high temperature thermocline system, with an experimental approach, taking in consideration industrial potential of such ceramics by making industrial mass production of such material realistic, using already widely available industrial processes from the bricks and tiles industries.Keywords: thermal storage, thermocline, experimental validation, waste heat, high temperature, sintered ceramics, incinerator bottom ash valorization

碩士
國立臺灣大學
化學工程學研究所
101
This thesis aims at developing a mathematical model for the synthesis of a heat exchanger network which can integrate with the organic rankine cycle (ORC) for recovery of low-grade waste heat. An integrated stagewise superstructure, which is analogous to the superstructure introduced by Yee and Grossmann for the synthesis of heat exchanger networks, is proposed for including the ORC as part of the heat recovery system. The integrated stagewise superstructure can represent all possible interconnections and interactions between process streams and the ORC. Based on this superstructure, the synthesis of heat exchanger networks with the ORC streams is formulated as a mixed-integer nonlinear program (MINLP). A two-steps solution method is suggested to solve the MINLP problem: (1) A heat exchanger network excluding the ORC is solved for minimizing the utility consumption; (2) Based on the results of step one, a modified network including the ORC below the pinch point is synthesized for maximizing the generated work from the ORC turbine. Some numerical examples from the literature are supplied to demonstrate the applicability the the proposed approach.

碩士
國立臺灣大學
生物產業機電工程學研究所
93
When meeting the shortage of fossil fuels and the coming era of hydrogen energy, fuel cell energy emerged to be a promising technology in energy utilization in the future. Developed to work at 800 to 1,000 degree Celsiusand and up to 15 atm (tested by Ontario Hydro Technology), solid oxide fuel cells (SOFCs) can generate the maximum power output among all types of fuel cells. However, when operating the SOFCs, great amount of fossil fuel is actually consumed in order to meet their high-temperature demand. High amount of secondary pollutants are expelled accordingly. A possible brand new idea is thus proposed in this paper—a state-of-the-art tubular SOFC (TSOFC) can be installed either in the three dimensional heat flow field inside the cement industrial rotary kiln incinerator (RKI, located in Kaohsiung, Taiwan) or within its refractory layer where high temperature environment sustains around the clock when operating for the cement production. In this paper, simulation of the heat flow field and species remained after combustion in this kiln incinerator is achieved with the help of modern computer aided engineering (CAE) tool. Suitable manipulating regions are to be found and predicted via the commercially available CFD code FLUENT. Parameter of excess air values are the primary variable, the detailed interior heat flow field and the heat transfer model in the kiln shell are the secondary variables for evaluating the installation of SOFCs into rotary kilns. Before going on this study, kinetic parameters are parametrically varied and finite volume method (FVM) is introduced to solve the heat flow field and the visualization of the three dimensional flame structure is performed. Meanwhile, simulation of temperature results is compared with on-site field experiments and the installation possibilities of the SOFC on the rotary kiln incinerator can be reasonably predicted and assured

A research report submitted to the Faculty of Engineering and Built Environment, University of the Witwatersrand, in partial fulfilment of the requirements for the degree of Master of Urban Studies in the field of Sustainable and Energy Efficient Cities, 2020
Waste energy from manufacturing industries is released as heat, steam or exhaust gases. These released energy forms contribute to the CO2 emissions of cities where these industries are situated. European countries at large have benefited from previous studies on the estimation of the waste heat recovery potential in industrial processes. Considerable progress into the reduction of energy use, cost and CO2 emission has been achieved in this region based on these findings. However, research into estimating waste heat recovery and re-use on a production-scale is not fully explored in South Africa due to several factors which include a lack of systemic approach, the cost of waste heat recovery framework, and inaccessible or inconsistent data sets. For this purpose, this study uses a bottom-up approach to assess the waste heat potential to be used for onsite work in three case study manufacturing industries in Johannesburg. Factory-level data consisting of CO2 emissions and energy consumption in selected case study manufacturing sites are used in this study to estimate the potential for waste heat recovery. Consideration was given to each manufacturing subsector-specific parameters, and the study finds that low to medium grade waste heat streams is contained in exhaust gases, air and vapour emitted from steam boiler systems, air compressors, heating, and drying processing units; which typically consume a high amount of energy and are generic processing units widely used in manufacturing industries. About 125,922.44 GJ (34, 978.3kWh) of waste heat with a work potential of between 18.93 to 29.4% representing about one-fifth to a third (20 -30 %) of the total estimated waste heat streams for all three selected manufacturing case studies was estimated in this research. Given that this waste heat stream is associated with carbon emissions from fossil fuel combustion during manufacturing activities; the study also finds that the recovery of waste heat promises about 7-24 % potential savings in energy consumption and about 60% reduction in CO2 emissions per year. In light of the finding from the study, it is logical to state that waste heat recovery has the potential for reducing energy demand and cost, as well as a significant reduction in carbon emission from manufacturing industries.
CK2021

Die Effektivität keramischer Wärmeübertrager kann durch eine feinere Strukturierung der Oberflächen gesteigert werden. Dies kann durch die Integration textiler Urformen anstatt der konventionell im Schlickguss hergestellten gröberen Geometrien erfolgen. Für Strukturierungen in Form von wandgebundenen Halbbögen werden die Ergebnisse umfangreicher experimenteller und numerischer Untersuchungen zu den wärmetechnischen und strömungsmechanischen Eigenschaften vorgestellt. Basierend auf den Erkenntnissen der mittels numerischer Simulation durchgeführten Parameterstudie werden verschiedene Empfehlungen für eine optimierte Anordnung der Halbbögen gegeben, um das Verhältnis von Wärmeübergang zur Druckverlust zu verbessern. Die experimentellen Ergebnisse belegen die Richtigkeit der gewählten Randbedingungen und Vereinfachungen im numerischen Modell. Des Weiteren wurden die Strömungsstrukturen mit laserdiagnostischen Messmethoden umfangreich charakterisiert.:0 Verwendete Symbole und Formelzeichen IV 1 Einleitung 1 1.1 Motivation 1 1.2 Lösungsansatz 2 1.3 Zielstellung und Struktur der Arbeit 4 2 Stand der Technik 5 2.1 Vorwort 5 2.2 Kennzahlen zur Charakterisierung von Rekuperatoren und Wärmeüber-trageroberflächen 6 2.3 Strömungszustände und Strömungsprofile 13 2.3.1 Grenzschichten von Strömungen 13 2.3.2 Laminare Strömung zwischen zwei parallelen Platten und im Rechteckkanal 14 2.3.3 Turbulente Strömung zwischen zwei parallelen Platten 15 2.3.4 Kenngrößen, Längen- und Zeitmaße von turbulenten Strömungen 16 2.4 Umströmung von Zylindern und Wärmeübergang an Zylindern 19 2.4.1 Quer angeströmter Zylinder, Wirbelablösung und Kármánsche Wirbelstraße 19 2.4.2 Hufeisenwirbel um einen wandgebundenen Zylinder 25 2.4.3 Zylinder in Wechselwirkung miteinander und Zylinder in Tandempaarung 27 2.4.4 Quer angeströmter Zylinder parallel zu einer Wand 28 2.5 Weitere den Wärmeübergang steigernde Strukturen 29 2.5.1 Rohrbündel 30 2.5.2 Stabrippen – „pin fins“ 31 2.5.3 Zweidimensionale Rippengeometrien 33 2.5.4 Gedrehte Bleche und andere Einbauten in Rohrquerschnitten 36 2.5.5 Turbulatoren 38 2.5.6 Poröse Körper 39 2.5.7 Drähte als wärmeübergangsteigernde Struktur 40 2.6 Wärmeübertrager für Industriegasbrenner 41 3 Numerische und experimentelle Untersuchungen der neuentwickelten Wärmeübertragerstruktur 45 4 Numerische Untersuchungen bezüglich des Strömungsfelds um die Bogenstrukturen 49 4.1 Randbedingungen und Vernetzung der numerischen Simulation 49 4.2 Bemerkungen zum Turbulenzmodell 54 4.3 Validierung des numerischen Modells am leeren Kanal 59 4.4 Ergebnisse für die Grundgeometrie 63 4.5 Parameterstudie zur Anordnung und Anzahl der Bögen 70 4.5.1 Variation der Bogendichte 70 4.5.2 Variation der Anordnung der Bögen zueinander bei konstanter Bogendichte 75 4.5.3 Variation der Kanalhöhe bei konstanten Randbedingungen 78 4.5.4 Variation der Kanalhöhe bei umgekehrten Randbedingungen 80 4.5.5 Variation des Bogendurchmessers D 82 4.5.6 Bemerkung zum Anstellwinkel 83 5 Experimentelle Untersuchungen zum Wärmeübergangskoeffizienten 85 5.1 Versuchsaufbau 85 5.2 Versuchsdurchführung und Auswertung 88 5.3 Vergleich des Versuchsstandes mit Untersuchungen für Spaltströmungen 90 5.4 Referenzmessungen mit metallischen Wärmeübertragerstrukturen 93 5.4.1 Ergebnisse für die Grundgeometrie 93 5.4.2 Variation der Kanalhöhe 96 5.4.3 Variation der Kanalhöhe bei umgekehrten Randbedingungen 97 5.5 Messung mit keramischen Strukturen 98 6 Experimentelle Untersuchungen zum Strömungsverhalten 101 6.1 Versuchsaufbau 101 6.2 PIV-Messungen 104 6.2.1 Allgemeines zum Messprinzip 104 6.2.2 Messaufbau 105 6.2.3 Versuchsergebnisse 106 6.3 LDA-Messungen 111 6.3.1 Allgemeines zum Messprinzip und zur Versuchsdurchführung 111 6.3.2 Validierung des Versuchsstandes 114 6.3.3 Strömungsprofile aus der LDA-Messung 117 6.3.4 Wirbelablösung im Bogennachlauf 130 6.3.5 Skalen der Strömung 144 7 Anwendungsbeispiel: Rekuperatorbrenner 151 7.1 Brennerprototyp und Versuchsdurchführung 151 7.2 Versuchsergebnisse und Auswertung 153 8 Zusammenfassung und Ausblick 157 9 Literaturverzeichnis 161 10 Anhang 173 10.1 Messtechnik des Windkanals 173 10.2 PIV-Messtechnik 175 10.3 LDA-Messtechnik 176 10.4 Versuche mit dem Rekuperatorprototypen 177

碩士
國立中山大學
高階經營碩士班
95
The shortage of energy supply against growing demand globally has caused seriously impact to all industries, dead or alive, especially for the energy intensified industries, like oil refinery (Petroleum) Iron and Steel making industries which has been confronting tremendously with pressing concern for survival. Even both industries are within traditional industrial factor, but represent as key and fundamental industries as relied on, by all industries of a Nation. Therefore, all the international enterprises dealing with high-temperature production have been striving for long-term supply & steady quality of raw material of energy. Under this circumstance, the enterprises shall be offering to find the measures for cost-down of energy consumed, and further utilize the waste gas and heat as generated out of the production, that would surely produce the efficiency of energy, and not only diminish the dependence on primary energy, it also can effectively reach the goal of “Independence of Energy” and optimization for the control of energy cost. This study is adopting the case study of Company “C”, with the analysis of SWOT, Five-force Analysis, and Diamond Model by Michael Porter, to further analyze the overall environment and circumstance of energy intensified industries. So that, it might help to understand further the strength and weakness of the energy intensified industries of our nation. First of all, to proceed the survey for the application of waste heat recovery system to energy intensified industries, and secondly, the application of waste heat recovery system to energy intensified industries in Taiwan, to generate direct and indirect efficiency whether or not to escalate the overall competitiveness to face the global competition. This research recognize the No. 1 pressure & bottle neck of the energy intensified industry lies mainly in the insufficiency of energy supply, and the upcoming environmental protection is getting more conscious & concerned. Therefore, all the industrialized countries have moved further forward to reinforce the energy saving technology, and increase the efficiency of energy using, developing new generation of energy with more efforts. Adoption of Company “C”, has recognized the following benefit, after the introduction of Waste Gas Heat Recovery System: 1. Recovery of Waste Gas of Hot Blast Stove, reduction of COG use, to transfer the saved COG to down-stream, to substitute the expensive natural gas, which is benefit to Company “C” in the respect of energy saving. 2. Increasing the operation efficiency of hot blast stove, to have operation technique more Sophisticated, in the meantime, to eradicate the moisture out of BFG/Air and further extend the life time of ceramic burner of hot blast stove. 3. The Waste Gas Heat Recovery System has been totally mature with good reference of operation in the world market, which has been used by most steel mills in the world. There is actually no risk to adopt and apply this technology, & further carve out the good image of company “C” in the respect of energy saving. 4. Reduction of SOx out of waste gas, and further diminish the temperature of waste gas released and can reduce the CO2 emission that is friendly to our environment. The research of this study recognized further, that energy intensified industry has been built up due to the scenario and situation of Taiwan in past few decades, in view of the development of economy, which is crucial industry & business sector. However, with the time running, the energy intensified industry requires to be adjusted for adaptation to the industrial environment of energy crisis and global warming. In this case, the largest potential worry for Taiwan is obviously insufficiency of energy supply. Furthermore, the technical level of energy saving of Taiwan is far more behind Japan, & many other European countries. General Speaking, the energy intensified industry of Taiwan is in weak situation at this moment. If Taiwan might introduce more advanced technology, and technical cooperation, technical research and development, or even training of qualified personnel enabling to upgrade the energy saving of Taiwan to be further upgraded for increasing the competitiveness of industries which is surely positive for a nation being more competitive. In view of energy intensified industry, shortage of energy supply and the price be kept high end, the recycling energy is not available within short time, for short and mid term, the best effective measures to solve the problem of energy is to reduce the amount of energy, for long run, it is great help to use the energy saving system to the energy intensified industry. For one hand, it might reduce the production cost; on the other hand, it can increase the energy operation efficiency. The heat pipe Waste Gas Heat Recovery System as described in this Study is well sound technology of energy saving.