Design and investigation of solar cogeneration system with packed bed thermal energy storage for ceramic industry

Abstract

A novel cogeneration system was designed with three different configurations integrating cogeneration system with solar-aided (Configuration-1), solar-aided with packed bed thermal energy storage (Configuration-2), solar-aided with packed bed thermal energy storage and auxiliary unit (Configuration-3). Thermo-economic-environmental analyses were performed for three designed configurations under Indian climatic conditions (20°C–50 °C).The maximum energetic and exergetic efficiencies of the three configurations were found as 44.96% and 23.14%, 51.84% and 31.22%, and 58.67% and 36.21%, respectively. Configuration-3 was best among others, and the sustainability index was 1.57. The maximum irreversibility rate has occurred for the combustion chamber, ground and wall tile dryer. The payback period for Configuration-3 was found as 4.91 years. Due to various unfavourable conditions, the payback period for Configuration-2 is 27% higher than Configuration-3. The economic optimization was performed for the higher payback period configuration, and the payback period was finally reduced to 4.88 years. The cost of the product from the cogeneration system, such as electricity and ground-wall tile was found as Rs.6.29/unit and Rs.16.11/piece for ceramic tile size of 0.10 × 0.10 × 0.007 m. The CO2/SO2/NOx emission from the three configurations was found as 1,54,090/119/230 ton/year, 1,31,341/102/196 ton/year, and 1,47,961/114/221 ton/year, respectively. Furthermore, the carbon emission saving for three configurations was obtained as 21%, 24%, and 32%, which is imperative for the environment.