Review of Research Problems and Methodologies · MW Kellogg Ltd (MWKL) Veolia (Sheffield Heat and...

Review of Research Problems and Methodologies

Jim Swithenbank (Chairman)

Newcastle, 26th January 2010

Main Objective

To investigate new and appropriate technologies and supporting measures needed to enhance and exploit the needed to enhance and exploit the large amount of unused low grade heat available from a wide range

of process industries

The Challenges and ActionsThe Challenges and Actions

The national input of energy (approx 100mT/yr fuel) is used approximately equally for: transport, domestic (largely heating buildings), and the process industry (including power production).

Recycle and reuse waste Low Grade Heat.

Communication, communication and communication: between industry and academe! Hence the need for this Network

Our joint Our joint Industry/academic Industry/academic approachapproach::

� A Parable! Coordinated by PRO-TEM

� Teamwork: Stakeholder input – the whole is more than the sum of the parts.

� Identify, communicate and achieve our final objective.

� Deliverable? A “virtual” manual for Stakeholders: Background (benefits), Case studies, Implementation Procedure.

Corus LtdNorth East Process Industry Cluster (NEPIC) E.ON UK, Ratcliffe-on-Soar:BP Chemical LtdAlstom Power Ltd

Some Industrial Partners:

Alstom Power LtdMW Kellogg Ltd (MWKL) Veolia (Sheffield Heat and Power Ltd)Pfizer Ltd.Juniper Ltd Evonik Degussa Seal Sands Ltd

EPSRC Energy ProgrammeEPSRC Energy ProgrammeDavid David HoltumHoltum (apology)(apology)

� Priority topic: Industry/Academe Team

� Low carbon future

� Strategic partnership with E.ON

� PRO-TEM Process Industry Thermal Energy Management Network: Website, Report bank, Forum Groups, Research vision, sustainable future, Final Report.

� Nine Research Projects Funded:

Research ProjectsResearch Projects

� Thermal Management of Industrial Processes: Sheffield, Newcastle, Manchester (CPI and Tyndall)

� Design Toolbox for Energy Efficiency in � Design Toolbox for Energy Efficiency in the Process Industry: UCL, Imp Coll.

� Energy Saving in the Foundry Industry: Birmingham


� Evaluation of a Large Energy Intensive Site (Centralised vs distributed generation): Cardiff

� Intensified Heat Transfer for Energy � Intensified Heat Transfer for Energy Saving in Process Industries: Bath

� Optimising Thermal Energy Recovery , Utilisation and Management in the Process Industries: Brunel, Newcastle, Northumbria


� Reduction of Energy Demand in Paper Making Using Online Optimisation and Control: Cambridge

� Thermal Management in Commercial � Thermal Management in Commercial Bread Baking: Leeds

� Thermal Management in Polymer Processing: Belfast, Bradford

Some SuggestionsSome Suggestions

� Avoid project duplication and overlap.

� Industry to establish academic links asap.

� Take full advantage of the Network.

� Consider opportunities for joint publications.� Consider opportunities for joint publications.

� Utilise Case Studies

� Exploit deliverables through industry.

� Consider ETI etc funding for implementation of concepts by industry. Up to 75% grants available.

Sheffield (EEE), Newcastle (SWAN), Manchester (CPI), Manchester (Tyndall)

Six Leading Areas of Research:

1 - Develop a database of the relevant energy sources in the process industry and its

potential uses. potential uses.

2 - Increase the amount of low grade heat that is available from the process industry

by new technology and neglected techniquessuch as condensing moisture from the flue gases.

3 - Assess opportunities for ‘over the fence’ external use of currently wasted process energy for local industrial or district heatingapplications.

4 - Analyse the opportunities to upgrade the energy, by heat pumps or drying “fuels”, and thus render the heat suitable for additional applications such as power generation.

5 - Advanced modelling of large scale over-the-fence process integration , together with system-wide modelling to take accountof the dynamic fluctuations in both energy supplies from the process and demand by supplies from the process and demand by the consumer.

6 – Assessment of the environmental benefits, wider socio-economic issues and political

impact that can be achieved.

EPRSC THERMAL MANAGEMENT OF INDUSTRIAL PROCESSES

Evaluation of the Biomass Drying Process

Researcher: Hanning Li

Investigators: Professor Jim SwithenbankProfessor Vida N. Sharifi

SUWIC, Sheffield University

Biomass Drying

Pulp & paper sludge Wood residues Bark Wood residues Chip Milled Peat Sugarcane BagassePulp & paper sludge

50%-60%

15-19

Wood residues Bark

30%-60%

19-25

Wood residues Chip

45%-55%

19-21

Milled Peat

45%-55%

19-21

Sugarcane Bagasse

48%-52%

18.6-20.3

MoistureHHV (dry base kJ/kg)

The benefits of biomass moisture less than 10%:

- wet fuel consumes some heat of combustion to evaporate water in the fuel

- Dried fuels lead to a high flame temperature

- a larger temperature gradient in the boiler is beneficial for radiant heat transfer

- more heat is released from the fuel

- lower carbon monoxide (CO) levels and less fly ash leaving the boiler

- less extra air required causing reduced power supply needed for air input

Biomass Drying – Commercial Dryers

Mediums:

- Air

- Flue gas

- SuperheatSteam

Rotary dryer Belt dryer Flash dryer Fluidized bed

Small particle

High corrosion

Fire risk after drying

Leakage in steam dryer

Variable particle sizes

Robust

Low temperature drying

Steam – heat recycle

Reasonable dimension

Steam – heat recycle

Uniform & low temperature

High M/H transfer

Variable particle sizes

Reasonable dimension

Robust

Larger dimension of dryer

Fire risk inside dryer

- high hazard risk

Corrosion and erosion

Blocked by long bark

Fire risk after drying

Small & uniform particle

Abrasion among particles

Leakage in steam dryer

Advantages

Disadvantages

Biomass Drying

Dryer types Manufactures Operation Parameters Costs

Rotary

Bacho Industry

Kirkenaer

MEC Company

Mitchell Dryers Ltd

Flue gas:

Temperature: 160-280 OC

Capacity: 800-7000 kg- H2O/h

Heat Consumption:

5.8 MJ/kg-H2O

include installation

$160-370/kg/h

$1.6-5.3 million

GEAFlue gas, steam:

Temperature: 150-700 OC include installation

Flash

GEA

DryCo

Einco

Temperature: 150-700 OC


Heat Consumption:

0.4-1.0 MJ/kg-H2O

include installation

$330-860/kg/h

$3.5-10.6 million

Fluidized Bed Niro A/S

Steam:

Temperature: 190 OC

Capacity: 3600 kg- H2O/h

no installation:

$4.5-7 million

Belt

Swiss Combi

Bruks Klockner

Andritz Fiber

Air:

temperature:30-110 OC


Biomass Drying – Other Commercial Options for Low Temperature Heating Sources

Renergi LTD DryerDry-Rex

Biomass Drying

Drying is an extra cost in process industries and power plants, even though this may be offset by smaller boiler, air emissions equipment and fuel handling equipment.

Biomass Drying– Case Study: Evaluation of the Biomass Drying Process

40% flue gas250 oC – 450 oC;647 - 336 t/h

60% hot water90 oC; 737 t/h

Heating Sources

100 MW

Biomass

Heating Sources

40 MW

Drying

Biomass Drying – Case Study

Mflue , HCf,in, Tf,in, Hf,in Mflue , HCf,out, Tf,out, Hf,out

Mwood, MCw,in, Tw,in, Hw,in Mwood, MCw,out, Tw,out, Hw,out

Mflue , Tf,,out

Dryer

Mass and Heat Balances:

Flue Gas Drying

MS, Ps,in, Ts,in, Hs,inMwat, Twat, Hwat

MS, Ps,out, Ts,out, Hs,out

Mwood, MCw,in,

Tw,in, Hw,in

Mwood, MCw,out,

Tw,out, Hw,out

Pre-heater

Dryer

R

Mflue , Tf,in

Mflue , Tf,,out

Steam Drying

Biomass Drying – Case Study

Mflue , HCf,out, Tf,out

Mwood, MCw,in, Tw,in Mwood, MCw,out, Tw,out

Mflue , HCf,in, Tf,in

A Continuous Cross-Flow Belt Dryer

.)./(

)(40 (kg/s)M wood

bdkgMJvalueheatingfuel

MWplantpowerininputpower

−=

)MC-(MCMW(kg/s) outinwood ×=

Biomass Drying – Estimation of Water Evaporation

)MC-(MCMW(kg/s) outinwood ×=

Moisture change (wt%-wet)

initial, final (kg/s) (t/h)

0.6, 0.1 3.3339 12.0019

0.6, 0.2 3.0005 10.8017

0.6, 0.3 2.5718 9.2586

gas) fluedry -(kJ/kgHH outf,inf, =

Biomass Drying – Estimation of Required Heating Sources

Adiabatic process:

ffvapourpAirp HCHCCC ×+×+= latentf,,f HT) (HEnthalpy of flue gas:

BA

+−=)(Plog sat10Antoine Equation: TC

A+

−=)(Plog sat10Antoine Equation:

sat

sat

air

water

PP

P

MW

MW

ϕ

ϕ

−×=HCHumidity:

Mass Flow Rateof flue gas: )/(

)/(G f

airkgwaterkgHCHC

swaterkgrateremovingwater

outin −−−

−=

Biomass Drying – Estimation of Required Heating Sources

Flue gas drying Steam drying

Steam drying Steam drying

Biomass Drying – Estimation of Capital Costs

∑= ieqCostG ,DCCost

Belt dryer: Cost eq=2700Y Y is cross-section area

Cover: Cost eq=1200Y0.5 Y is cover area

Cost functions (€):

Direct Capital Cost:

Heat exchanger: Cost eq=660Y0.7 Y is heat transfer area

G (Lang factor) is selected as 1.6, including 0.1 for electricity, 0.1 for instrumentation, 0.05 for lagging, 0.15 for civil work,0.2 for installation.


load

woodwood

W

MCM τ×+=

)1(A eff

Mwood: solid mass flow rates

MC: moisture content

W : solid loading (30kg/m2)

Belt Cross-sectional area:

Wload: solid loading (30kg/m2)

Heat exchanger area:

)(A exchangerheat

watf TTh

Q

−×=

τwood: solid residence time

Q: Heat transfer flow rate

h: Heat transfer coefficient

Tf: flue gas temperature

Twat: water temperature


Flue gas drying Steam drying

Biomass Drying – Estimation of Profitability

Capitalenancema C

C−

+

−= ∑

=

=

kt

0tt

intt

i)(1

C t)NPV(projec

Cmaintenance=0.05 CCapital

Ct= (HCsave - Q × HCflue gas) × τop

HCsave= Weva× Hlatent × HCfuel

HCflue gas: price of flue gas (0.5 €/GWH)

HCfuel: price of biomass fuel (6-20 €/MWH)

Weva: water evaporation rate (kg/s)

Hlatent: latent heat of water (kJ/kg)

Q: heating rate for water evaporation (kJ/s)

i: interest; t: year; τop: 8400 h/year


Flue gas drying

Initial MC=1.5 kg-w/kg-wood

Cumulative cash flow 10 year NPV

Final MC=0.1, 0.3 kg-w/kg-wood Final MC=0.1 kg-w/kg-woodFuel price = 14 €/MWH Fuel price = 14 €/MWH


Steam drying

Cumulative cash flow 10 year NPV

Final MC=0.1, 0.3 kg-w/kg-wood Final MC=0.1 kg-w/kg-woodFuel price = 14 €/MWH Fuel price = 14 €/MWH


Effect of fuel prices

Initial MC=1.5 kg-w/kg-wood

Final MC=0.1 kg-w/kg-wood

10 year NPV

Bacho industryKirkenaerMEC companyMitchell Dryers Ltd

Rotary

Belt

Flash

GEA; DryCo; Einco

Flue gas150-700 C

* 10000-26000 kg/h** 3.7 MJ/kg-H2O

Steam150 C

* 6000-30000 kg/h** 0.4-1.0 MJ/kg-H2O

Fluidized Bed

Niro A/S

Steam190 C

* 3600 kg/hFlue gas160-280 C

* 800-7000 kg/h

**5.8 MJ/kg-H2O

Cost (not including

Biomass Drying – commercial dryers

* Evaporation rate of water ** Heat consumption

Belt

Swiss Combi, Bruks Klöckner, Mabarex, Andritz Fiber

** 0.4-1.0 MJ/kg-H2O

Air30-110 C

* 500-40000 kg/h

Cost (not includingInstallation):$22-106 /kg/h Including installation-$300-796 /kg/h ,$1.6-5.3 millionfor 15-130 MW bioler;

-$761 /kg/h$ 5.4 millionfor 55 tonnes/h boiler

Cost (excluding installation)

$ 18-160 /kg/h

Including installation

-$335/kg/h, 180tonnes/h

burning bark

-$550-1600 /kg/h

$ 3.5-10.6 million

for 15-130 MW boiler

Biomass Drying – Superheated Steam

Basic IVO dryer (Imatran Voima Oy )

IVO dryer ( a bed mixing dryer)

Superheated steam systems based on Flash dryer

Steam is condensed to recapture the latent heat, compressed to a higher pressure operation, then injected into a gas turbine.

Dryer sizes:

55 tonnes/h

for drying

biomass from

60% to 40%

MoDo dryer

It was used with a fluidized bed

gasifier or boiler. The sensible heat

from the bed material evaporates water from fuel

The walls of flash tube are heated with high-temperature steam, providing the heat to evaporate the water in biomass

The capital cost

(MoDo dryer):

USD$330/kg/h

Biomass Drying – other options

Advantages:- high power density-reducing drying time- high energy efficiency, avoid warm up and cool down- improved quality, compared with conventional drying.- avoids combustible gas by- products, environmental friendly

Disadvantages:- not uniform dried (hot spot or cold spot)- penetration achievable, depended on biomass properties.- insufficient knowledge of the interaction between wood

Microwave dryer

- insufficient knowledge of the interaction between wood and process parameters as well as the higher investment expenses.

Supercritical CO2Advantages: - using CO2(green house gas)- low temperature (saving energy)- low fire risk- high quality (avoiding high temperature heating biomass)

Disadvantages:- high pressure equipmentand processes

Task3 Task3 -- Sheffield ; high efficiencySheffield ; high efficiency

� Novel technology

� Industrial condensing boilers

� Low temperature, < dew point

� Boiler design

� External system

Condensing boilersCondensing boilers� Benefits:

– High efficiency: recovery of sensible and latent heat

– Emission reduction: absorption by the condensate

Dew point

Dew point

Re-vaporisation of the condensate

Condensing boilersCondensing boilers

� Risks:

– Corrosion: acid condensate due to sulphur and nitrogen impurities

– Relatively high investment and maintenance costs

Condensing boilersCondensing boilers� Application/Case Studies

– Oriketo heating station in Finland (Condenser: 12MWth)

– Vimmerby Energy AB in Sweden (Condenser: 2MWth)

– CHP power plant in Harnosand, Sweden (11 MWe, 26MWth, Condenser: 7MWth)

– Nitrate Stress Corrosion Cracking in Waste Heat Recovery Boilers in the Netherlands in 1990’s (Leferink et al. 2003)

» Ammonia Nitrate» Ammonia Nitrate

» Carbon steel and low alloy steel are sensitive to attack

Oriketo heating station

Condensing boilers with Radiator & floor heatingCondensing boilers with Radiator & floor heating

� Return water from a heating system should be 30-50°C, well below the dew point of flue gas

� A floor heating system or large surface area radiator is required.

Condensing boilers with a heat pumpCondensing boilers with a heat pump

� A heat pump can be used between the condenser and the hot return water– Conventional electrically driven compression heat pump

– An absorption heat pump

Thermoacoustic EngineThermoacoustic Engine� Thermoacoustic engines of which nearly all are thermoacoustic

stirling engines;

� It is a technology that uses high-amplitude sound waves in a pressurized gas to pump heat from one place to another;

� or uses a heat temperature difference to induce sound, which can be converted to electricity with high efficiency, with a (piezoelectric) loudspeaker;(piezoelectric) loudspeaker;

� The most efficient thermoacoustic devices built to date have an efficiency approaching 40% of the Carnot limit, or about 20% to 30% overall (depending on the heat engine temperatures).

Thermoacoustics Engine Thermoacoustics Engine (Standing (Standing --wave)wave)

Stack Total power

Acoustic power

Standing-wave engine example, Scale drawing, and power distribution of Tektronix researchers (G. W. Swift, 2002)

Branch to refrigerator

InsulationAmbient heat exchanger

Stack

Hot heat exchanger138 cm

Branch

Thermoacoustics Engine Thermoacoustics Engine (Traveling(Traveling--wave)wave)

Tapered pulse tube

Regenerator

Traveling-wave refrigerator example, Schematic and power distribution: Cryenco 2-kW orifice pulse-tube refrigerator (G.

W. Swift, 2002)

Acoustic power

Total power

Thermoacoustic Engine (Malone Thermoacoustic Engine (Malone Refrigeration)Refrigeration)

Thermoacoustic refrigeratorThe Sonic Compressor

Stakeholder InputStakeholder Input

� Industrial Partners

– Other industrial participants

– Co-opted partners– Co-opted partners

Task 1. National sources of low grade heat available from the process industry- Led by Newcastle University

Research Tasks

Task 2. Identification of potential uses of the energy and their relative location. - Led by Newcastle University.

Task 3. Novel technologies to increase the amount of low grade heat available from process industries.Led by Sheffield University.

Task 4. Novel technologies to increase the efficiency of using the low-grade thermal energy for district heating. Led by Sheffield University

Task 5. Novel technologies to upgrade the heat and thus render it suitable for additional applications. Led by Sheffield University

Task 6. System-wide Modelling and optimisation with Advanced Process Integration for Low Grade Heat RecoveryLed by CPI (Manchester University)

Task 7.Environmental and Socio-EconomicIssues. Led by Tyndall Centre, Manchester University

Task 8. Final Report.- All Partners

Danish Integrated Boilers/Combined Cycle CHP network of units

1 - Four partner workshops for rapid and efficient technology transfer.

2 - Three comprehensive interim Reports at six month intervals plus the Final Report

Deliverables:

six month intervals plus the Final Report and an associated automated decision-support tool .

3 - Publications in high impact refereed journals.

4 – ‘Exploitation’ of the concurrent and future EPSRC Network and web site .

5 - Dissemination of policy-relevant 5 - Dissemination of policy-relevant recommendations to stakeholders in an appropriate form. It is envisaged that the Network will be the major route for wider dissemination.

Project Work Plan

Task4 Task4 -- Sheffield; district heatingSheffield; district heating

� Novel technology

� Industrial waste heat

� Low temperature return;

– Large radiators

– Underfloor heating

– Integrate with other sources; e.g. biomass

� System growth; e.g. Barnsley

Task5 Task5 –– Sheffield; heat upgradeSheffield; heat upgrade

� Novel technologies

a) Mechanical heat pump systems

b) Thermo-acoustic heat pump

1) Wave generation

2) Energy removal

3) Efficiency and cost

c) Drying biomass

Review of Research Problems and Methodologies · MW Kellogg Ltd (MWKL) Veolia (Sheffield Heat and...

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