12. WS Effective use of thermal energy in industry_CIC EnergiGUNE

VI CDTI-NEDO JOINT WORKSHOP

Thermal Energy Storage in industrial processes

CIC energiGUNE

Javier RodríguezGroup Leader

Thermal EnergyStorage

Bilbao, 23rd June 2016

#WasteHeat The Effective use of termal energy in industry

01About CIC energiGUNE…

MISSION

Above 150 million invested and more than 500 researchers working in

critical areas with relevant facilities and under a collaboration framework.



Energy efficiency for industrial

processes

High temp. Industrial processes

Concentrated solar Plants

CharacterisationMaterial

Synthesis

Prototyping

Lab-testing

Computational

modeling

Energy Storage Types: Electrochemical Storage (EES): power storage; batteries and supercaps

Thermal Storage: Heat storage


04Industrial Waste Heat

From the basic thermodynamics…

Heat engine

QH

QL

TH

TL

S. Carnot (1824)“The efficiency of a quasi-static or reversible Carnot cycle depends only on the temperatures of the two heat reservoirs, and is the same, whatever the working substance. A Carnot engine operated in this way is the most efficient possible heat engine using those two temperatures”

0T

QS

STWQWU

Low grade heat. Wasted heat.



…to the real application:

“Working with thermal engines, or temperature driven processes, there is no way to obtain a fully reversible thermal process. Part of the thermal energy will be lost on the process”

Capture of the waste heat. Thermal Energy Storage

Intensive heat demanding industrial activities present large thermal energy losses. Theselosses lead to:1. Noticeably decrease of the overall industrial process efficiency2. Oversized process input energy3. Large environmental impact, in terms of greenhouse emissions4. High economic cost in terms of input energy, CO2 emissions etc.5. …

How to minimize the impact of these thermal losses on the overall industrial process?


Technical potential for waste heat in German industry (AG Energiebilanz 2007). Description Final Energy Waste heat percentage above 140 °C of the final energy

consumption Waste heat



Distribution of heat demand according to temperature levels and industries EU (Wagner 2002)



Technical Potential for Waste heat recovery in the US Manufacturing Sector (Oak Ridge National Laboratory, 2015)


In the Basque Country:

Around 200 M€ are lost in waste heat annually!

In the US:

The waste heat recovery in industrial processes presents a huge potential!


Raw material… …Tranformation process… Final product…

Qin Qout

Qin QinQout Qout

P1T1

P2T2

P3T3

To the heat storage• Waste heat stream: Transfer fluid, Radiative flow…• Flow rate?• Temperature?

Heat storage:• What TES Technology?• What is the

application of the stored heat?

From the heat storage• Hot fluid flow• Flow rate?• Temperature?• Application of the stored heat?

The selection of a heat storage technology is driven by the industrial

process and the application of the stored heat


Different heat storage technologies proposed from CIC

energiGUNE for industrial waste heat recovery


11Solutions, technology, capacities: Latent Heat Storage

Sugar alcohols encapsulated in carbon matrixes for enhanced heat

Macropore size: 50 to 600 m; Wall thickness: 10 to 20 m

•Melting temperature: 110 ºC•High energy density: 330 J/g•Enhanced thermal transport due to the high conductive porous carbon matrix

Encapsulated sugar alcohols for low temperature PCM storage

Main benefits of latent heat storage compared with standard sensible storage:• Constant operation temperature• High energy density

Latent Heat Storage


The use of eutectic metal alloys is proposed as latent heat storage material

• Constant and appropriate phase change temperature (Up to 400 ºC)

• High energy density• High thermal conductivity

1. Simple heat exchanger designs.2. Fast thermal response3. High power level4. Versatiliity: Air, Salt, Oil etc operation (non-direct contact)

Potential applications:• Direct steam generation• Industrial heat recovery• High power applications• Fast thermal response• Short operation time requirements (transients)

New concept of thermal energy storage

Mg-Zn-Al

κ=75 W/mK

Tm=335-340 ºC

ΔH=140-170 J/g

Metal alloys High temperature PCM storage

12Solutions, technology, capacities: Latent Heat Storage


Potential applications of this system: CSP storage units: Single tank high solution Versatile storage: Flexible operation temperature, fluid flow, temperature

range/tolerances etc. Industrial heat recovery: High temperature heat recovery in steel, glass,

ceramic, foundry industry

Direct contact between the fluid (air, salt, oil etc.) and the storagematerial: No heat exchanger needed!Different solid materials with potential application: Valorization of industrial by-products as TES material.Cost effective storage concepts (Thermocline based).High temperature storage (Up to 1200 ºC).

13Solutions, technology, capacities: Sensible Heat Storage

Solid Packed Bed for a high temperature flexible storage

Sensible Heat StorageSensible storage operation:• Constant/Non-constant operation temperature depending on the storage solution• Liquid/Solid storage solutions: Molten salt, Enhanced molten salt, Solid packed bed etc.• Cost effective solution• Extended operation temperature range


Heat storage in conventional molten salt mixtures

Demonstrated technology in different environments (CSP, industrial applications etc.) Operation temperature range 280-550 ºCLow thermal conductivity value ≈ 0.5 W/mKCost…

14

Enhanced molten salt mixtures (Research stage…)

New salts formulations to extend the working temperature range between the melting and

decomposition temperatures

New nitrite salts and study of their stabilities,

Structural and thermophysical characterizations of the new salts

Commercial salt modification

Microscopic modeling the ternary and quaternary salt systems

Experimental study of the ternary and quaternary systems.

Solutions, technology, capacities: Sensible Heat Storage


Determination of proper constituents and their proper proportions to best balance thermal

energy storage, heat transfer and system cost.

Characterization of the thermophysical properties of the composite material:

• Specific heat,

• Thermal conductivity,

• Latent heat.

Demonstrating the cost effective of the composite material

Stability study of the composite material with common stainless

steels

Determination of the economic benefit by using the composite

material as TES material in a concentrating solar power. “Effect of nanoparticle dispersions in binary nitrate salt as thermal

energy storage material in concentrated solar power applications”,

Bharath Dudda, University of Texas 2013.

Enhanced molten salt mixtures:

Nanoparticle dispersion indifferent molten salt compositions: Research stage…

15Solutions, technology, capacities: Sensible Heat Storage


Main aim

Decrease of the environmental impact of landfill of steel slag by turning waste slag from the steel industry into useful feedstock for other industrial sectors leading to close loop processes

Objectives Environment:

Reduction of landfilled steel slag (25% of the total, around 3 Mton) Heat recovery and CO2 reduction Primary raw material reduction.

Operative: Building and validation of 4 pilot system:

1. Non-ferrous high value metal extraction from slag2. Shaped pebbles for TES applications to recover heat in thermal

energy intensive industries3. TES material to be used for CSP plants4. Production of innovative refractory ceramic compounds.

Social, sectorial and policy : To contribute to a close to zero waste Steel Sector To improve industry competitiveness in a wide number of sectors Provide to the EU with the main social, environmental, energetic and organizational outputs derived from RESLAG project.

4 Innovative alternatives to valorize an industrial waste by-product in new applications

16R&D projects: RESLAG project


Turning waste from steel industry into valuable low cost feedstock for energy intensive industry

19 EU Partners

8.5 M€ Budget

Coordinator: CIC Energigune

TRL: 5 - 7

42 Months

17R&D projects


PROJECT ACTION

OUTCOME Industrial partner Research partner

PILOT 1High added metals

extraction technology (Cu, Cr, Ni, Zn etc)

PILOT 2

Heat recovery systems technology. TES system for waste heat recovery up to

800 ºC

PILOT 3AThermocline TES system using slag

and air.

PILOT3BThermocline TES system using slagand molten salt.

PILOT 4Refractory ceramics with slag waste in their composition.

All pilotsExploitation,

dissemination andLife Cycle Assesment

18R&D projects


Impact management of the expected results from RESLAG project

Identification and quantification of

the RESLAG project impact. LCA

Up-scaling of the pilots. Lab-Pilot-industrial scale. Feasibility and performance assessment.

Benchmarking

Economic & environmental

evaluation. Customization.

Market & application identification.

Main actor & interest mapping.

Risk evaluation

The interest on the exploitation of the results obtained from RESLAG is also manifested by different industries

Solar developments

System & Engineering development

FoundryCement production Steel & tubular

productsIron/Steel industry

Glass production

Renewable energies

Automotive

19R&D projects


Heat storage technologies show a large implementatin potential:

• Low/High operation temperature

• Constant/Non-constant operation temperature

• Large-term storages

• Fast and high power storages

• Liquid/Solid storage solutions

• …

Potential application:

• Power requirements?

• Fluid flow requirements?

• Temperature level, tolerances etc.?

20Other interesting information: Exploitation of TES

• Direct steam generation

• Industrial heat recovery: From

Batch to Continuous heat/power

supply

• Process/component pre-heating

• Electricity production: Steam cycle,

ORC cycle.

• Dispatchable energy: Uncoupling

the generation/demand process

• From low to high temperature

applications

• Long-term storages

• Seasonal storage applications

A wide variety of heat storage alternatives…

The final selection of a storage technology is driven by the application…

• Customization

• Adapted technology to optimize the thermal performance


21Ideas for a Japan Spain collaboration

Potential Key collaborations:

1. New materials for heat storage: Materials with enhanced heat transport properties

1. New storage materials for low-high operation temperature. Sensible and latent operation

2. New heat transfer fluids. Improved durability, transfer properties. Modified fluids

2. Innovative heat storage solutions: Sensible, latent heat storage

1. Enhancement of state-of-art technologies: Packed bed, Fluidized bed, heat exchange/storage

systems

2. New heat management solutions in heavy industries. Optimization of the heat demanding

processes.

3. Development of computational models to describe:

1. Microscopic behaviour / design of new materials for energy storage

2. Macroscopic behaviour, heat transfer and fluidic behaviour, of new storage technologies

4. Experimental testing on realistic air, molten salt and thermal oil TES testing facilities

THANK YOU

どうも有難う御座います

ESKERRIK ASKO

GRACIAS

Javier Rodríguez

[email protected]

CIC energiGUNE

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