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.

Techno-economic feasibility assessment of a diesel exhaust heat recovery system to preheat mine intake air in remote cold climate regions

Underground mines in Arctic and Subarctic regions require the preheating of mine intake air during winter.The cold fresh air of those remote areas can be as severe as
40℃ and commonly needs to be heated to around+3℃.This extensive amount of heating is usually provided by employing large-size air heaters,fueled by diesel,propane,natural gas,or heavy oil,leading to high energy costs and large carbon footprints.At the same time,the thermal energy content of a diesel generator sets(gen-sets)exhaust is known to be one-third of the total heating value of its combusted fuel.Exhaust heat recovery from diesel gen-sets is a growing technology that seeks to mitigate the energy costs by capturing and redirecting this commonly rejected exhaust heat to other applications such as space heating or pre-heating of the mine intake air.The present study investigated the possibility of employing a simple system based on off-theshelf heat exchanger technology,which can recover the waste heat from the exhaust of the power generation units(diesel gen-sets)in an off-grid,cold,remote mine in Canada for heating of the mine intake air.Data from a real mine was used for the analysis along with environmental data of three different location-scenarios with distinct climates.After developing a thermodynamic model,the heat savings were calculated,and an economic feasibility evaluation was performed.The proposed system was found highly viable with annual savings of up to C$6.7 million and capable enough to provide an average of around 75%of the heating demand for mine intake air,leading to a payback period of about eleven months or less for all scenarios.Deployment of seasonal thermal energy storage has also been recommended to mitigate the mismatch between supply and demand,mainly in summertime,possibly allowing the system to eliminate fuel costs for intake air heating.

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.

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.

Heat Recovery from Automotive Exhaust Using Heat Pipes with Limited Fluid Charge

Experiments were conducted in this study to examine the thermal performance of a thermosyphon,made from Inconel alloy 625,could recover waste heat from automobile exhaust using a limited amount of fluid.The thermosyphon has an outer diameter of 27 mm,a thickness of 2.6 mm,and an overall length of 483 mm.The study involved directing exhaust gas onto the evaporator.This length includes a 180-mm evaporator,a 70-mm adiabatic section,a 223-mm condenser,and a 97-mm finned exchanger.The study examined the thermal performance of the thermosyphon under exhaust flow rates ranging from 0–10 g/sec and temperatures varying from 300℃–900℃.The influence of three parameters—inclination angle(5°–45°),water mass(2–5.3 g),and the quantity of non-condensable gas Argon(0–0.6 g)—was investigated to assess their impacts on the thermosyphon’s thermal efficiency.The experimental findings revealed that with 3 g of water and 0.0564 g of argon in the thermosyphon,the condenser reached its highest temperature at around 200℃.The ideal fuel loading rate for the thermosyphon falls between 0.2 and 0.7 g/s.Moreover,as inclination angles rise,outer wall temperatures of the thermosyphon increase.This is attributed to the explicit expansion of the effective heating area within the evaporation section,coupled with an amplified gravitational component of the water flux.Additionally,an upsurge in the quantity of non-condensable gas(NCG)can mitigate temperature gradients on the outer wall,resulting in a decline in the thermosyphon’s performance.The insulation applied to the adiabatic section demonstrated efficacy in augmenting temperature gradients on the outer wall,thereby improving the overall performance of the thermosyphon.As the water charge within the thermosyphon increases,there is a corresponding rise in heat transfer rates both from the exhaust to the thermosyphon and from the thermosyphon to the fuel.

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 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.

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.

Simulation of Gas-Fired Triple-Effect LiBr/Water Absorption Cooling System with Exhaust Heat Recovery Generator

An exhaust heat recovery generator is proposed to be integrated with conventional gas-fired triple-effect LiBr/water absorption cooling cycles to improve system energy efficiency. As a case study, simulation of the novel cycle based on promising parallel flow with cooling capacity of 1 150 kW is carried out under various heat recovery generator vapor production ratios ranging from 0 to 3.5%. The life cycle saving economic analysis, for which the annual gas conservation is estimated with Bin method, is employed to prove the worthiness of extra expenditure. Results show that the optimum gas saving revenue is obtained at 2.8% heat recovery generator vapor production ratio with 42 kW exhaust heat recovered, and the system energy efficiency is improved from 1.78 to 1.83. The initial investment of exchanger can be paid back within 7 years and 9 000 CNY of gas saving revenue will be achieved over the 15-year life cycle of the machine. This technology can be easily implemented and present desirable economic effects, which is feasible to the development of triple-effect absorption cycles.

Performance and Optimization for a Ground-Coupled Liquid Loop Heat Recovery Ventilation System

Ground-coupled heat pumps(GCHP)are commonly used in residential heating system.To mitigate the boreholes temperature dropping with operating time,a new exhaust-air recharging system is developed.The new recharging system can be used in three operational modes.In this paper,a ground-coupled heat recovery ventilation(HRV)model is discussed.A thermal model is set up to find the optimal brine flow rate and heat transfer allocation ratio between exhaust and supply coils for maximum heat recovery efficiency.Contrary to the conventional liquid-loop HRV systems,the brine temperature entering the exhaust coil never goes blow zero(0℃),and hence defrosting is needless in the ground-coupled HRV system.This can make the ground-coupled HRV system over 20% more efficient than a conventional HRV system at low outdoor temperatures.

Characterization of a new total heat recovery system using CaCl_(2) as working fluid:Thermal modeling and physical analysis

This paper introduces a kind of open cycle absorption heat wet flue gas heat recovery system,which use CaCl_(2) as the working medium.The system will use the wet heat recovery method and combined with an efficient heat pump system for flue gas as a heat source generator.Through direct contact with the solution in the absorber,the flue gas is going to carry out gas,liquid heat transfer between heat exchanger,realization of sensible heat and latent heat step by step.As the key part of the system,absorber is established by one-dimensional steady-state heat transfer and mass transfer model.This paper uses the finite difference method to model the discrete numerical methods,and an-alyzes the characteristics of heat and mass transfer in the absorber.We obtain the concentration curves of the three kinds of working medium’s temperature and flow along the height direction.We also analyze the influence of CaCl_(2) solution parameters changes on the absorption process,parsing the reason of the temperature change by analyzing the three working medium’s energy flow trend.We found that the temperature change of flue gas is non-monotonic,which decreases gradually in the range of absorption tower height 0-0.9 m,and then increases gradually.The reason for this change is that sensible heat exchange and latent heat exchange exist between flue gas and solution.Although such a change has an impact on the efficiency of the system,it prevents the"white smoke"from condensing in the air,which effectively protects the environment.Compared with conventional LiBr absorption heat pump,the system constructed in this paper has certain advantages in latent heat recovery,flue gas heat energy utilization,energy conservation and emission reduction and economy.

Finite-Time Thermodynamic Simulation of Circulating Direct Condensation Heat Recovery on Chillers

A time series model is used in this paper to describe the progress of circulating direct condensation heat recovery of the compound condensing process (CCP) which is made of two water cooling condensing processes in series for a centrifugal chiller in the paper. A finite-time thermodynamics method is used to set up the time series simulation model. As a result, an upper bound of recoverable condensation heat for the compound condensing process is obtained which is in good agreement with experimental result. And the result is valuable and useful to optimization design of condensing heat recovery.

A four-dimensional interaction-based appraisal approach towards the performance enhancement of a vehicular waste heat recovery system

The non-linear multifactorial impacts on fuel-saving potential constrain the practical performance of the vehicular waste heat recovery system(WHRS). This study proposed a four-dimensional interaction-based appraisal approach to interpreting these impacts for enhancing WHRS's in-vehicle performance. The interaction incorporates a heat exchanger, configuration, engine,and vehicle. The proposed approach comprises two successive steps, emphasizing evaluation under the rated(Step 1) and off-design(Step 2) heat source conditions. A case study of waste heat recovery from a passenger vehicle was conducted to evaluate the in-vehicle performance of a novel co-split system and two single-split ones(with/without a regenerator) through this approach. The novel system theoretically modifies vehicular performance but remains ambiguous concerning real-world behaviour, which is assessed and verified by the proposed approach. Two key factors determining vehicular performance were identified by Step 1, namely, net power output and engine backpressure. As the co-split system modified both factors, its fuel-saving potential could be increased by up to 20.3% compared with single-split systems. Also, the limiting factor for off-design performance was pinpointed by Step 2, namely, the mismatch between the heat source and working fluid, which led to the solution, i.e., the synergistic split regulation of the working fluid and heat source. An up to 8.8% improvement in net power output was achieved by the co-split system at off-design heat sources compared with fixed split ratios. Consequently, the approach enables holistic performance improvement of the vehicular WHRS under design/off-design heat source conditions.

The heat recovery simulation in the system of dry granulation of the steel slag

In present,the wet-based pattern is mainly adopted to deal with the steel slag by steel plant at home and abroad,the wet-based technology has some defects;Wasting of water,pollution of the environment,and the slag has not been fully recycled.This paper presents a new method,which is aimed to realize dry granulation,waste heat recovery and comprehensive utilizing the steel slag.According to the ideas of wind quenching granulation,the heating slag from the converter furnace,was bring to the granulation heat exchange system,through the process of breaking in a container,the granulation heat exchange system has the functions of feeding continuously and heat exchange.The heat air,through the diversion tubes,could be recycled in removing the dust.The granulation slag could be bring to a confined roller,granulating and cooling secondarily.The roller export was connected to a magnetic separator.The separated iron could be recycled,and the remaining slag could also be reused as building materials,in process of stabilization and secondary magnetic separation.The heated air could be guided into the boiler to generate the steam,which can be used to generate electricity,or use as cleaned energy,realizing the target to recycle the waste heat in steel slag.The highlights of the new method are dry granulation and waste heat recovery.This paper states the process of heat exchange between the air and the steel slag in the system of granulation heat exchange in the new technical process.In theory,it has been proved reasonable with the the system of granulation heat exchange,and also the work conditions has been optimized.

A Study of the Jet System of the Recovery Concerning Waste Heat of Steam Condensate

This paper presents a frame figure of the recovery system concerning waste heat of steam condensate. When steam phase changes into liquid state in the condenser, the heat equilibium equation, gas state equation, mass flow calculating equation of the jet steam and incondensable gas equation are established. The coupling function between condensate unit and recovery pump of the hot condensate with ejector is studied. The paper sets up the fluid continuity equation, heat equilibium equation and efficiency equation of the ejector and points out the technical key how the prevent hot condensate change into steam phase. When fluid passes from circulation loop through pump to export, the energy equations are obtained here. At last, signal figure of the applied examples are given and settle the techanical questions of the jet system are discussed.

Steady-State Modeling of Heat Transfer on the Recovery System of Condensing Boiler

The increase of energy production is very important nowadays. It is necessary to improve the performance and efficiency of heat production facilities. The objective is to reduce pollutant emissions and regulate investment costs. One of the solutions is to control fuel and electricity consumption. This article develops a new model of simulation heat diffusion on the recovery system of condensing boiler. The method is based on the first and second thermodynamic systems. The Numerical discrete Model (NDM) was applied using MATLAB to simulate different characteristics of heat transfer in the recovery system. The result shows that the recovery unit can absorb the following temperatures;the range from 88°C to 90.7°C when the length of the tube is between respectively 110 and 111 m. the energy efficiency was between 0.55 and 0.57 which allowed confirming the model. This new model has some advantages such as;the use of an instantaneous calculation time. The heat recovered by the water tank can also serve as preheating different systems. One part of the heat recovered will be accumulated to be used as domestic hot water.

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

Performance Assessment of a Heat Recovery Unit Utilizing Turbine with Variable Inlet Guide Vanes Configuration for Application in Passenger Vehicles

This study explores the potentials of employing an Organic Rankine Cycle (ORC) system with variable inlet guide vanes (VIV) turbine geometry designed on a GT-Suite platform for effective exhaust heat recovery (EHR) application onboard passenger vehicles. The ORC model simulation was based on vehicle speed mode using R245fa as working fluid to assess the thermal performance of the ORC system when utilizing modified turbine geometry. Interestingly, the model achieved a very improved performance in contrast to the model without a modified turbine configuration. The results revealed the average 2.32 kW ORC net output, 4.93% thermal efficiency, 6.1% mechanical efficiency, and 5.0% improved brake specific fuel consumption (BSFC) for the developed model. As determined by the performance indicators, these promising results from the model study show the prospect of EHR technology application in the transportation sector for reduction in exhaust emissions and fuel savings.

Exploring heating performance of gas engine heat pump with heat recovery

In order to evaluate the heating performance of gas engine heat pump（GEHP） for air-conditioning and hot water supply, a test facility was developed and experiments were performed over a wide range of engine speed（1400-2600 r/min）, ambient air temperature（2.4-17.8 ℃） and condenser water inlet temperature（30-50℃）. The results show that as engine speed increases from 1400 r/min to 2600 r/min, the total heating capacity and energy consumption increase by about 30% and 89%, respectively; while the heat pump coefficient of performance（COP） and system primary energy ratio（PER） decrease by 44% and 31%, respectively. With the increase of ambient air temperature from 2.4 ℃ to 17.8 ℃, the heat pump COP and system PER increase by 32% and 19%, respectively. Moreover, the heat pump COP and system PER decrease by 27% and 15%, respectively, when the condenser water inlet temperature changes from 30 ℃ to 50 ℃. So, it is obvious that the effect of engine speed on the performance is more significant than the effects of ambient air temperature and condenser water inlet temperature.

Optimizing Low-Temperature Heat Recovery in a Refinery Fluid Catalytic Cracking Unit Based on Pinch Analysis

In this paper, the research was focused on optimizing low-temperature heat recovery to adopt multi-effect distil- lation （MED） in desalination by pinch technology. And further analysis indicated that phase changes occurred during the heat recovery process. In such case, the feed stream was divided into two streams： the liquid feed stream and the gaseous feed stream. Through calculation, the optimal ATmin was established at 26℃, and the total cost of heat exchange process was only $1.098× 106. By using the Problem Table Algorithm for pinch analysis, the temperature of the hot and the cold steams was 119℃ and 93 ℃, respectively. At a temperature higher than 119 ℃, all heat of the hot stream could not be cooled by the condenser, and the minimum heat load of utility （QH.min） was 440457.64 kW; and at a temperature below 93 ℃, all heat of the cold stream could not be provided by the heater, and the minimum cold load of utility （QC.min） was 1965993.85 kW. Finally, the synthesis of heat exchanger network was established through integrating two heat exchanger networks.