Waste heat recovery from hot steel slag on the production line:Numerical simulation,validation and industrial test

Waste heat recovery from hot steel slag was determined in a granular bed through the combination of numerical simulation and an industrial test method.First,the effective thermal conductivity of the granular bed was calculated.Then,the unsteady-state model was used to simulate the heat recovery under three different flow fields(O-type,S-type,and nonshielding type(Nontype)).Second,the simulation results were validated by in-situ industrial experiments.The two methods confirmed that the heat recovery efficiencies of the flow fields from high to low followed the order of Nontype,S-type,and O-type.Finally,heat recovery was carried out under the Nontype flow field in an industrial test.The heat recovery efficiency increased from~76%and~78%to~81%when the steel slag thickness decreased from 400 and 300 to 200 mm,corresponding to reductions in the steel slag mass from 3.96 and 2.97 to 1.98 t with a blower air volume of 14687 m^(3)/h.Therefore,the research results showed that numerical simulation can not only guide experiments on waste heat recovery but also optimize the flow field.Most importantly,the method proposed in this paper has achieved higher waste heat recovery from hot steel slag in industrial scale.

Off-Design Simulation of a CSP Power Plant Integrated with aWaste Heat Recovery System

Concentrating Solar Power(CSP)plants offer a promising way to generate low-emission energy.However,these plants face challenges such as reduced sunlight during winter and cloudy days,despite being located in high solar radiation areas.Furthermore,their dispatch capacities and yields can be affected by high electricity consumption,particularly at night.The present work aims to develop an off-design model that evaluates the hourly and annual performances of a parabolic trough power plant(PTPP)equipped with a waste heat recovery system.The study aims to compare the performances of this new layout with those of the conventional Andasol 1 plant,with the aim of assessing the improvements achieved in the new design.Based on the results,it can be concluded that the new layout has increased the annual generated power to almost 183 GWh(an increase of about 7.60% is achieved compared to the Andasol 1 layout that generates 169 GWh annually).Additionally,the proposed installation has achieved an efficiency of 20.55%,which represents a 7.87% increase compared to the previous design(19.05%).The Levelized Cost of Electricity(LCOE)of the new layout has been reduced by more than 5.8% compared to the Andasol 1 plant.Specifically,it has decreased from 13.11 to 12.35 c/kWh.This reduction in LCOE highlights the improved cost-effectiveness of the newlayout,making it amore economically viable option for generating electricity compared to the conventional Andasol 1 plant.

Dynamic test on waste heat recovery system with organic Rankine cycle

Dynamic performance is important to the controlling and monitoring of the organic Rankine cycle(ORC) system so to avoid the occurrence of unwanted conditions. A small scale waste heat recovery system with organic Rankine cycle was constructed and the dynamic behavior was presented. In the dynamic test, the pump was stopped and then started. In addition, there was a step change of the flue gas volume flow rate and the converter frequency of multistage pump, respectively. The results indicate that the working fluid flow rate has the shortest response time, followed by the expander inlet pressure and the expander inlet temperature.The operation frequency of pump is a key parameter for the ORC system. Due to a step change of pump frequency(39.49-35.24 Hz),the expander efficiency and thermal efficiency drop by 16% and 21% within 2 min, respectively. Besides, the saturated mixture can lead to an increase of the expander rotation speed.

Application of the waste heat recovery system and energy-saving in the strip continuous annealing furnace

The common problem of cold strip continuous annealing furnaces is high exhaust gas temperature and great energy consumption. Taking the cold-strip continuous annealing furnaces of Baosteel No. 4 cold mill plant as an example, several waste heat recovery systems in the annealing furnaces are compared and their advantages and disadvantages are analyzed through different energy-saving technologies.

Optimal Analysis of Pure Low-Temperature Waste Heat Recovery Generation System

In this paper, a detailed thermodynamic analysis of the pure low-temperature waste heat recovery generation system is presented. The parameters affecting the system performance are compared to obtain the most significant ones; furthermore, parameter values are optimized for the largest power generating capability of the system. It is found that the most important parameters are inlet flue gas temperature, steam pressure and the pinch point temperature difference. There is an optimal superheated steam pressure value for giving the maximum generation power per unit flue gas. With the increase of inlet flue gas temperature, the generating power increases and the optimized steam pressure rises as well. However, with increase in pinch point temperature difference, the generating power decreases and the optimized steam pressure decreases as well. The theoretical calculation provides a theoretical basis for the parameters optimization in the design of the pure low-temperature waste heat recovery eeneration swtem

Integration of Low-level Waste Heat Recovery and Liquefied Nature Gas Cold Energy Utilization

Two novel thermal cycles based on Brayton cycle and Rankine cycle are proposed, respectively, which integrate the recovery of low-level waste heat and Liquefied Nature Gas （LNG） cold energy utilization for power generation. Cascade utilization of energy is realized in the two thermal cycles, where low-level waste heat,low-temperature exergy and pressure exergy of LNG are utilized efficiently through the system synthesis. The simulations are carried out using the commercial Aspen Plus 10.2, and the results are analyzed. Compared with the conventional Brayton cycle and Rankine cycle, the two novel cycles bring 60.94% and 60% in exergy efficiency, respectively and 53.08% and 52.31% in thermal efficiency, respectively.

Machine learning-based multi-objective optimization and thermal assessment of supercritical CO_(2) Rankine cycles for gas turbine waste heat recovery

Technologies for utilizing waste heat for power generation have attracted significant attention in recent years due to their potential to enhance energy efficiency and reduce greenhouse gas emissions.This research focuses on the comparative and optimization analysis of three supercritical carbon dioxide(sCO_(2))Rankine cycles(simple,cascade,and split)for gas turbine waste heat recuperation.The study begins with parametric analysis,investigating the significant effects of key variables,including turbine inlet temperature,condenser inlet temperature,and pinch point temperature,on the thermal performance of advanced sCO_(2) power cycles.To identify the most efficient cycle configuration,a multi-objective optimization approach is employed.This approach combines a Genetic Algorithm with machine learning regression models(Random Forest,XGBoost,Artificial Neural Network,Ridge Regression,and K-Nearest Neighbors)to predict cycle performance using a dataset extracted from cycle simulations.The decision-making process for determining the optimal cycle configuration is facilitated by the TOPSIS(technique for order of preference by similarity to the ideal solution)method.The study's major findings reveal that the split cycle outperforms the simple and cascade configurations in terms of power generation across various operating conditions.The optimized split cycle not only demonstrates superior power output but also exhibits enhanced net power output,heat recovery,system and exergy efficiency of 7.99 MW,76.17%,26.86%and 57.96%,respectively,making it a promising choice for waste heat recovery applications.This research has the potential to contribute to the advancement and widespread adoption of waste heat recovery in energy technologies boosting system efficiency and economic feasibility.It provides a new perspective for future research,contributing to the improvement of energy generation infrastructure.

Assessment of Low Global Warming Potential Refrigerants for Waste Heat Recovery in Data Center with On-Chip Two-Phase Cooling Loop

Data centers(DCs)are highly energy-intensive facilities,where about 30%–50%of the power consumed is attributable to the cooling of information technology equipment.This makes liquid cooling,especially in twophase mode,as an alternative to air cooling for the microprocessors in servers of interest.The need to meet the increased power density of server racks in high-performance DCs,along with the push towards lower global warming potential(GWP)refrigerants due to environmental concerns,has motivated research on the selection of two-phase heat transfer fluids for cooling servers while simultaneously recovering waste heat.With this regard,a heat pump-assisted absorption chiller(HPAAC)system for recovering waste heat in DCs with an on-chip twophase cooling loop driven by the compressor is proposed in the present paper and the low GWP hydrofluoroolefin refrigerants,including R1224yd(Z),R1233zd(E),R1234yf,R1234ze(E),R1234ze(Z),R1243zf and R1336mzz(Z),are evaluated and compared against R245fa as server coolant.For theHPAAC system,beginning with the development of energy and economic models,the performance is analyzed through both a parametric study and optimization using the coefficient of performance(COP),energy saving ratio(ESR),payback period(PBP)and net present value(NPV)as thermo-economic indicators.Using a standard vapor compression cooling system as a benchmark,the results indicate that with the evaporation temperature between 50℃and 70℃and the subcooling degree ranging from5℃to 15°C,R1233zd(E)with moderate compressor suction pressure and pressure ratio is the best refrigerant for the HPAAC systemwhile R1234yf performs the worst.More importantly,R1233zd(E)is also superior to R245fa based on thermo-economic performance,especially under work conditions with relatively lower evaporation temperature as well as subcooling degree.Under the given working conditions,the overall COP,ESR,NPV,and PBP of R1233zd(E)HPAAC with optimum subcooling degree range from4.99 to 11.27,25.53 to 64.59,1.13 to 4.10×10^(7) CNY and 5.77 to 2.22 years,respectively.Besides,the thermo-economic performance of R1233zd(E)HPAAC under optimum working conditions in terms of subcooling degree varying with the evaporation temperature is also investigated.

A review on current development of thermophotovoltaic technology in heat recovery

The burning of fossil fuels in industry results in significant carbon emissions,and the heat generated is often not fully utilized.For high-temperature industries,thermophotovoltaics(TPVs)is an effective method for waste heat recovery.This review covers two aspects of high-efficiency TPV systems and industrial waste heat applications.At the system level,representative results of TPV complete the systems,while selective emitters and photovoltaic cells in the last decade are compiled.The key points of components to improve the energy conversion efficiency are further analyzed,and the related micro/nano-fabrication methods are introduced.At the application level,the feasibility of TPV applications in high-temperature industries is shown from the world waste heat utilization situation.The potential of TPV in waste heat recovery and carbon neutrality is illustrated with the steel industry as an example.

Energy,Exergy,and Exergoeconomic Analysis of Solar-Driven Solid Oxide Electrolyzer System Integrated with Waste Heat Recovery for Syngas Production

Syngas fuel generated by solar energy integrating with fuel cell technology is one of the promising methods for future green energy solutions to carbon neutrality.This paper designs a novel solar-driven solid oxide electrolyzer system integrated with waste heat for syngas production.Solar photovoltaic and parabolic trough collecter together drive the solid oxide electrolysis cell to improve system efficiency.The thermodynamic models of components are established,and the energy,exergy,and exergoeconomic analysis are conducted to evaluate the system’s performance.Under the design work conditions,the solar photovoltaic accounts for 88.46%of total exergy destruction caused by its less conversion efficiency.The exergoeconomic analysis indicates that the fuel cell component has a high exergoeconomic factor of 89.56%due to the large capital investment cost.The impacts of key parameters such as current density,operating temperature,pressure and mole fraction on system performances are discussed.The results demonstrate that the optimal energy and exergy efficiencies are achieved at 19.04%and 19.90%when the temperature,pressure,and molar fraction of H_(2)O are 1223.15 K,0.1 MPa,and 50%,respectively.

Effect of flue gas outlet temperature in evaporator on thermal economic performance of organic Rankine cycle system for sinter waste heat recovery

In order to improve the recovery and utilization rates of sinter waste heat effectively,the organic Rankine cycle(ORC)system with subcritical cycle was designed to recover the low-temperature sinter cooling flue gas waste heat in an annular cooler for power generation.The thermodynamic,economic and multi-objective optimization models of ORC system were established,and R600a was selected as the ORC working medium.Subsequently,the variations in system thermodynamic performance and economic performance with the ORC thermal parameters were discussed in detail,and the optimal ORC thermal parameters were determined.The results show that the system net output power increases with increasing the evaporation temperature and decreasing the condensation temperature and increases first and then,decreases with the increase in superheat degree for a given flue gas outlet temperature in the evaporator,while the heat transfer area per unit net output power appears different variation trends in various ranges of flue gas outlet temperature.Taking the sinter cooling flue gas waste heat of 160℃as the ORC heat source,the optimal thermal parameters of ORC system were the flue gas outlet temperature of 90℃,the evaporation temperature of 95℃,the superheat degree of 10℃,and the condensation temperature of 28℃.

Simulation Analysis of Flue Gas Waste Heat Utilization Retrofit Based on ORC System

Recovery of waste heat from boiler flue gas is an effective way to improve energy utilization efficiency.Taking a heating station heating project as an example,the existing heating system of this heating station was analyzed for its underutilized flue gas waste heat and low energy utilization rate.Rankine cycle is an effective waste heat recovery method,and a steam boiler organic Rankine cycle(ORC)cogeneration waste heat utilization method is proposed.The system model simulation is constructed and verified.First,a thermodynamic model was constructed in MATLAB and five suitable work gases were selected to analyze the effects of evaporation temperature and condensation temperature on the network and thermal efficiency of the waste heat cycle power system.Secondly,the ORC model is invoked in TRNSYS to construct the improved cogeneration system,and the rationality of the remaining heat utilization methods is determined by calculating and analyzing the thermal performance,economy,and environmental protection of the improved system.The simulation results show that the system can generate about 552,000 kWh of electricity per year,and improving the energy utilization rate from 0.72 to 0.78.

Waste heat recovery from heavy-duty diesel engine exhaust gases by medium temperature ORC system

A medium-temperature waste-heat recovery system based on the organic Rankine cycle (ORC) is designed to recover the exhaust energy from a heavy-duty diesel engine. Analysis of the 1st law of thermodynamics for an ORC system is performed. This analysis contains two parts. The first part is an analysis with undefined heat exchangers to gain an understanding of the ORC and find out suitable organic fluid parameters for a better ORC efficiency. The second part of the analysis uses combined engine test results and two designs of heat exchangers. By comparing the two designs, an improved system of heat exchangers is described. This analysis also quantifies the effect of engine parameters on ORC system. The study concludes that the supercritical Rankine cycle is a better approach towards waste heat recovery. The ORC system is found to perform better under part-load conditions if the medium-high power condition rather than rated working point of the engine is used as the design parameter. The ORC system achieves the highest waste-heat recovery efficiency of up to 10-15% for the optimised heat ex-changer design.

Energy management strategy for hybrid electric vehicle integrated with waste heat recovery system based on deep reinforcement learning

Hybrid electric vehicles(HEVs)are acknowledged to be an effective way to improve the efficiency of internal combustion engines(ICEs)and reduce fuel consumption.Although the ICE in an HEV can maintain high efficiency during driving,its thermal efficiency is approximately 40%,and the rest of the fuel energy is discharged through different kinds of waste heat.Therefore,it is important to recover the engine waste heat.Because of the great waste heat recovery performance of the organic Rankine cycle(ORC),an HEV integrated with an ORC(HEV-ORC)has been proposed.However,the addition of ORC creates a stiff and multi-energy problem,greatly increasing the complexity of the energy management system(EMS).Considering the great potential of deep reinforcement learning(DRL)for solving complex control problems,this work proposes a DRL-based EMS for an HEV-ORC.The simulation results demonstrate that the DRL-based EMS can save 2%more fuel energy than the rule-based EMS because the former provides higher average efficiencies for both engine and motor,as well as more stable ORC power and battery state.Furthermore,the battery always has sufficient capacity to store the ORC power.Consequently,DRL showed great potential for solving complex energy management problems.

A review of concentrated photovoltaic-thermal(CPVT) hybrid solar systems with waste heat recovery(WHR)

In conventional photovoltaic(PV) systems, a large portion of solar energy is dissipated as waste heat since the generating efficiency is usually less than 30%. As the dissipated heat can be recovered for various applications, the wasted heat recovery concentrator PV/thermal(WHR CPVT) hybrid systems have been developed. They can provide both electricity and usable heat by combining thermal systems with concentrator PV(CPV) module, which dramatically improves the overall conversion efficiency of solar energy.This paper systematically and comprehensively reviews the research and development of WHR CPVT systems. WHR CPVT systems with innovative design configurations, different theoretical evaluation models and experimental test processes for several implementations are presented in an integrated manner. We aim to provide a global point of view on the research trends, market potential, technical obstacles, and the future work which is required in the development of WHR CPVT technology. Possibly, it will offer a generic guide to the investigators who are interested in the study of WHR CPVT systems.

Study on pneumatic-fuel hybrid system based on waste heat recovery from cooling water of internal combustion engine

The paper proposes a novel pneumatic-fuel hybrid system,which combines a traditional internal combustion engine(ICE)and a pneumatic engine.One important merit of this concept is that the system can recover waste from cooling water of internal combustion engine to optimize the working process of pneumatic engine,and thus to improve the entire efficiency of the hybrid system.Meanwhile,energy-saving effect due to lower cooling fan power can be achieved on ICE by waste heat recovery of pneumatic engine.Based on thermodynamic analysis,an experimental system is designed and established for verification.The experimental results show that the performance of pneumatic engine is improved when the waste heat recovery concept of the hybrid system is applied.Then an application example on a 4-cylinder engine is analyzed and discussed using numerical simulation.The results show that the fan power of the ICE cooling system can be saved up to 50%by applying the hybrid system.Considering the appreciable improvements on the energy efficiency with only limited system modifications when the concept is applied to traditional ICE based power systems,the proposed hybrid concept has the potential to serve as an alternative technology aiming for energy saving and emission reduction.

Overall optimization of Rankine cycle system for waste heat recovery of heavy-duty vehicle diesel engines considering the cooling power consumption

The Rankine cycle system for waste heat recovery of heavy-duty vehicle diesel engines has been regarded as a promising tech- nique to reduce fuel consumption. Its heat dissipation in the condensation process, however, should be take：l away in time, which is an energy-consuming process. A fan-assisted auxiliary water-cooling system is employed in this paper. Results at 1300 r/min and 50% load indicate that the cooling pump and cooling fan together consume 7.66% of the recovered power. What＇s worse for the heavy load, cooling accessories may deplete of all the recovered power of the Rankine cycle system. Af- terwards, effects of the condensing pressure and water feeding temperature are investigated, based on which a cooling power consumption model is established. Finally, an overall efficiency optimization is conducted to balance the electric power gener- ation and cooling power consumption, taking condensing pressure, pressure ratio and exhaust bypass valve as major variables. The research suggests that the priority is to increase condensing pressure and open exhaust bypass valve appropriately at high speed and heavy load to reduce the cooling power consumption, while at low speed and light load, a lower condensing pressure is favored and the exhaust bypass valve should be closed making the waste heat recovered as much as possible. Within the sub-critical region, a larger pressure ratio yields higher overall efficiency improvement at medium-low speed and load. But the effects taper off at high speed and heavy load. For a given vehicular heavy-duty diesel engine, the overall e：＇ficiency can be improved by 3.37% at 1300 r/min and 25% load using a Rankine cycle system to recover exhaust energy. The improvement becomes smaller as engine speed and load become higher.

Analysis of an electricity-cooling cogeneration system for waste heat recovery of gaseous fuel engines

Waste heat recovery(WHR)is one of the most useful ways to improve the efficiency of internal combustion engines,and an electricity-cooling cogeneration system(ECCS)based on Rankin-absorption refrigeration combined cycle for the WHR of gaseous fuel engines is proposed in the paper.This system can avoid wasting the heat in condenser so that the efficiency of the whole WHR system improves,but the condensing temperature of Rankin cycle(RC)must increase in order to use absorption refrigeration system,which leads to the decrease of RC output power.Therefore,the relationship between the profit of absorption refrigeration system and the loss of RC in this combined system is the mainly studied content in the paper.Because the energy quality of cooling and electricity are different,cooling power in absorption refrigeration is converted to corresponding electrical power consumed by electric cooling system,which is defined as equivalent electrical power.With this method,the effects of some important operation parameters on the performance of the ECCS are researched,and the equivalent efficiency,exergy efficiency and primary energy rate are compared in the paper.

Thermodynamic and Economic Studies of a Combined Cycle for Waste Heat Recovery of Marine Diesel Engine

In the present study,the thermodynamic and economic performance of a combined thermodynamic cycle formed by an ORC and a Kalina cycle,which can simultaneously recover waste heat of exhaust gas and cooling water of marine engine,has been analyzed.Two typical marine engines are selected to be the waste heat source.Six economic indicators are used to analyze the economic performance of this combined thermodynamic cycle system with different marine engine load and under practical comprehensive operating condition of marine engine.The results of the present study show that the combined thermodynamic cycle system with R123 as organic working fluid has the best performance.The system with cis-butene has the worst economic performance.Under practical comprehensive operating conditions of ships,R123 has the shortest Payback Periods,which are 8.51 years and 8.14 years for 8 S70 ME-C10.5 engine and 5G95 ME-C10.5 engine,respectively.Correspondingly,payback Periods of Cyclopentane are 11.95 years and 11.90 years.The above values are much shorter than 25 years which are the lifetime of a marine ship.Under practical comprehensive operating conditions of ships,the combined cycle system can provide output power which is at least equivalent to 25%of engine power.Considering that R123 will be phased out in near future,cyclopentane may be its good successor.Cyclopentane can be used safely by correct handling and installing according to manufacturer's instructions.

Comprehensive evaluation of marine waste heat recovery technologies based on Hierarchy-Grey correlation analysis

In this study,comprehensive evaluation of the technologies on waste heat recovery technologies for maritime applications has been carried out.We have focused our research on exhaust gas turbine system(EGT),thermodynamic organic rankine cycle(RC),Kalina cycle(KC)and thermoelectric generators(TG),which are the most appropriate and most up-to-date techniques for recovering power from marine engines.Each technology has its own advantages and disadvantages,so the comprehensive evaluation of these technologies is essential to accurately determine which technology will be applied to which target.This belongs to the multi-criteria decision(MCDM)process.The combined assessment methodology,consisting of gray correlation and analysis hierarchy processes,has been applied to evaluate four waste heat recovery techniques in terms of technical,economic,social and environmental aspects.According to the comparison results,the exhaust gas turbine system has been evaluated as the most promising technology among the various WHR technologies that can be applied to marine engines.Sensitivity analysis suggests that if investment cost of TG falls to about the same level as the one of EGT,TG could be the best method among these technologies.Reduction of investment cost of TG technology could be realized by development of low cost thermoelectric material.We have analyzed the correlation between each cost through DOE analysis and investigate the effect of individual costs on the total cost.This work helps in identifying the most suitable heat recovery technologies for marine engine.