Waste Heat Recovery Applications Research Articles

Review of Recent Applications of Heat Pipe Heat Exchanger Use for Waste Heat Recovery

With the reduction in fossil fuels and growing concerns about global warming, energy has become one of the most important issues facing humanity. It is crucial to improve energy utilization efficiency and promote a low-carbon transition. In comparison with traditional heat exchangers, heat pipe heat exchangers indicate high compactness, a flexible arrangement, complete separation of hot and cold fluids, good isothermal operations, etc. As a result, heat pipe heat exchangers have attracted wide attention and application in various fields in recent years. This paper provides an overview of the application of heat pipe heat exchangers, with a focus on the application in waste heat recovery, and analyzes the opportunities and challenges of heat pipe heat exchanger applications based on existing publications.

Machine learning-based multi-objective optimization and thermal assessment of supercritical CO2 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 (sCO2) 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 sCO2 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.

Using compressor inlet cooling process for a supercritical Brayton cycle with various supercritical gases to recover the waste heat from a biomass-driven open Brayton cycle

The heat loss of a biomass-driven open Brayton cycle (OBC) is recuperated in the current research with the help of a supercritical Brayton cycle (SBC) and a thermoelectric generator (TEG). The temperature of the gas entering the SBC compressor is reduced through an ammonia-water absorption chiller (ACH) for performance improvement. The SBC compressor inlet cooling is examined for four supercritical gases (Nitrogen, Carbon monoxide, Air, and Helium). Moreover, the best performance of the configuration with compressor inlet cooling is compared with that of the system without compressor inlet cooling. Although compressor inlet cooling brings about the most improvement in output electricity of the SBC in the case of helium, the exergy efficiency (ηex) of the system and unit cost of the product (UCP) do not improve as much as other gases due to the reduction in the output power of the TEG in the case of helium. In addition, helium conduces to the lowest ηex (38.29 %) and highest UCP (17.62 $GJ−1) among the gases. Hence, helium is unsuitable for the SBC in total waste heat recovery applications. On the contrary, air induces the best performance with an ηex of 39.6 % and a UCP of 17.3 $GJ−1. The enhancement in ηex is 6.66 % points when the waste heat of the OBC is fully recovered.

Numerical investigation of coupled heat transfer and flow characteristics in helical coil heat exchanger for mine water waste heat recovery

To efficiently recover waste heat from mine water, this study numerically investigates the flow and heat transfer performance of a tube-shell coupled helical coil heat exchanger (HCHE), under high Reynolds number conditions. The effects of inlet water temperature, mass flow rate (m), tube diameter (d), and helix pitch (P) on the tube side, shell side, and overall performance are analyzed. Performance metrics include friction factor (f), Nusselt number (Nu), overall heat transfer coefficient (U), heat transfer rate, and the Performance Evaluation Criteria (PEC) number. Specifically, this study focuses on detailed observation and analysis of the shell-side flow and temperature fields. Findings reveal that enlarging d from 30 mm to 50 mm results in a 32.55% decrease in U, whereas increasing P from 50 mm to 200 mm boosts U by 8.02%. The highest PEC number of HCHE is 2.43, observed in conditions of P = 50 mm, d = 30 mm, and mc = 4 × 103 kg/h. Correlations for fc, Nuc, and Nush are proposed based on simulation results. This study provides a theoretical basis for the design and structural optimization of HCHE in the mine water waste heat recovery applications.

Liquid metal-enhanced thermoelectric generator for high-temperature thermal harvesting

It is a challenge to achieve high output power of the thermoelectric generator (TEG) for high-temperature waste heat recovery due to the working fluids with low thermal conductivity (such as air) or low tolerance of temperature (water or oil). In this paper, the gallium-based liquid metal (LM) with a high boiling point (>1000 ℃) and thermal conductivity (>20 W/mK) are introduced to significantly enhance heat charging and discharging at the hot/cold sides of TEG. We also developed an electromagnetic induction pumping method for the effective LM-driven flow at high temperatures. A three-dimensional coupling multi-parameter optimization simulation model of LM-based TEG was developed to reveal the internal heat transfer and power generation mechanism for clarifying the impact factors of the performance. The results have shown that the power generation capacity can be effectively improved by increasing the inlet temperature (Thot-in). It is worth noting that the temperature difference (ΔT) of the TEG module is severely limited by the thermal resistance (Rcapacity) of the LM heat capacity, such as, when the flow rate of 2 L/min, the Rcapacity accounts for 90.6 % (0.020 ℃/W). It is easier to achieve a larger open circuit voltage by increasing the height of the thermoelectric leg, but the Pmax is constantly weakened. Compared with Xceltherm 600 and Solar salt, LM heat transfer fluid has more obvious advantages in enhancing the power generation performance of the system. The LM-based TEG experiment platform was established to study heat transfer and power generation characteristics. The results have demonstrated that good consistency was proved by comparing experimental and numerical data. And the Pmax of the LM-based TEG system is 0.16 W/cm2 at ΔT of 136 ℃. LM-based TEG can open new perspectives for broad applications in high-temperature waste heat recovery.

Maximizing energy efficiency in wastewater treatment plants: A data-driven approach for waste heat recovery and an economic analysis using Organic Rankine Cycle and thermal energy storage

Maximizing energy efficiency through waste heat recovery (WHR) processes is crucial for sustainable and eco-friendly operations across multiple industries, notably in wastewater treatment plants (WWTPs). This work proposes a comprehensive approach for assessing the WHR feasibility in WWTPs, structured in two main objectives. Firstly, an Artificial Neural Network (ANN) model is developed to accurately predict WHR based on operational data, including biogas temperature, biogas pressure, daily production in kWh, and WHR values in kWhth. The second objective focuses on economically evaluating the WHR feasibility based on the estimated WHR values obtained by the ANN model, and then realistically assessing the economic feasibility of integrating the Organic Rankine Cycle (ORC) and Seasonal Thermal Energy Storage (STES) systems. With an application to the As-Samra WWTP located in Jordan, the developed ANN model demonstrates promising results in the validation phase, with a root mean square error (RMSE) of 2206 kWh/day, a mean absolute error (MAE) of 1674 kWh/day, and an R-squared (R2) value of 68%. On the other hand, the economic analysis reveals that an optimal ORC system of 412.14 kWe capacity yields a Net Present Value (NPV) of 2.09 million US dollars, a Levelized Cost of Energy (LCOE) of 0.0749 USD/kWh, a Payback Period (PBP) of 4.8 years, and annual revenues of 428 kUSD. This work also investigates the techno-economic feasibility of integrating ORC-STES. Results indicate that the LCOE and PBP are highly affected by the ORC's capital cost, and integrating STES increases the LCOE to 0.0824 USD/kWh, rendering its integration with ORC infeasible. This study aims to advance the understanding and application of WHR in WWTPs, paving the way for more efficient and sustainable practices in the field.

Thermo-fluid dynamic modeling of a supercritical carbon dioxide compressor for waste heat recovery applications

The development of novel technical solutions for the efficient recovery of waste heat is crucial for making accessible the large amount of thermal energy released by industrial processes, thus supporting the EU energy strategy. To this end, the EU-H2020 project CO2OLHEAT aims at developing and demonstrating a novel sCO2 power unit of 2 MW capacity, recovering energy from flue gases at 400 °C. The CO2OLHEAT system features a relatively unconventional multi-shaft configuration where the sCO2 compressor is driven by a dedicated radial expander, while the electrical power is generated via a separated axial turbine.The present study focuses on the design and fluid-dynamic analysis of the CO2OLHEAT compressor. The thermodynamic optimization of the cycle led to an overall pressure ratio slightly above 2.5, delivered with a two-stage centrifugal compressor. As typically found in sCO2 power systems, the thermodynamic state of the fluid at the machine intake (P = 85 bar; T = 32 °C) is close to the critical point and to the saturation curve; therefore, the first stage of the machine demands a dedicated aero-thermodynamic design, which can account for the effects of non-ideal thermodynamics and of the potential onset of two-phase flows. The paper discusses the conceptual aero-mechanical design of the compressor and then focuses on its performance assessment over the full operating range via Computational Fluid Dynamics. Two alternative CFD models are applied, the first one based on the barotropic fluid representation and the second one featuring a complete thermodynamic model, both of them assuming homogeneous equilibrium in presence of multi-phase flows. The experimental validation and the application of the two models are presented and discussed. They are shown to provide similar outcomes, and indicate that the compressor fulfills the system requirement and guarantees wide rangeability. A thorough comparison between the CFD results highlights the implications of the underlying physical differences between the models, thus allowing to properly evaluate their use for the aerodynamic design and analysis of sCO2 compressors.

Multiscale Length Structural Investigation and Thermoelectric Performance of Double-Filled Sr0.2Yb0.2Co4Sb12: An Exceptional Thermal Conductivity Reduction by Filler Segregation to the Grain Boundaries.

Among thermoelectric materials, skutterudites are the most prominent candidates in the mid-temperature range applications. In the multiple-filled Sr0.2Yb0.2Co4Sb12 skutterudite, with Sr and Yb as fillers, we have enhanced the thermoelectric performance of CoSb3 through the reduction of lattice thermal conductivity and the optimization of carrier concentration and electrical conductivity. The high-pressure synthesis of the double-filled derivative promotes filling fraction fluctuation. This is observed by high angular resolution synchrotron X-ray diffraction, showing a phase segregation that corresponds to an inhomogeneous distribution of the filler atoms, located at the 2a positions of the cubic space group Im3̅. In addition, scanning transmission electron microscopy (STEM) combined with EELS spectroscopy clearly shows a segregation of Sr atoms from the surface of the grains, which is compatible with the synchrotron X-ray powder diffraction results. Mean square displacement parameters analysis results in Einstein temperatures of ∼94 and ∼67 K for Sr and Yb, respectively, and a Debye temperature of ∼250 K. The strong effect on resonant and disorder scattering yields a significantly lower lattice thermal conductivity of 2.5 W m-1 K-1 at 773 K. Still, good weighed-mobility values were obtained, with high filling fraction of the Yb and Sr elements. This drives a reduced electrical resistivity of 2.1 × 10-5 Ω m, which leads to a peak zT of 0.26 at 773 K. The analysis and results performed for the synthesized (Sr,Yb)-double filled CoSb3, shed light on skutterudites for potential waste-heat recovery applications.

Experimental and simulation study on a zeotropic ORC system using R1234ze(E)/R245fa as working fluid

Organic Rankine Cycle (ORC) is a highly promising technology for converting heat to power, which has a widespread application in renewable energy utilization and waste heat recovery. Zeotropic working fluids are widely investigated to enhance the performance of ORC. In the present study, an experimental study on zeotropic mixture R1234ze(E)/R245fa is conducted under specified operating conditions and the operating behaviors of the ORC system are evaluated. An ORC simulation model (BP-ORC) based on a back propagation neural network and heat exchanger simulation modules is developed. The contribution factors that trigger the differences in heat transfer and system performance among the various working fluids are investigated. The operating behaviors of the heat exchangers and system are simulated for the working conditions beyond the experimental study. R1234ze(E)/R245fa (0.25:0.75 and 0.50:0.50) features a wider operating range of mass flowrate than R245fa due to their relatively lower density. The net power output of R1234ze(E)/R245fa (0.50:0.50) is 4.63 % higher than that of R245fa at a mass flow rate of 0.164 kg/s due to its relatively higher heat transfer performance. The variation of density and operating pressure plays a significant role in influencing the heat transfer behaviors and system performances.

Numerical investigation of latent heat storage unit with dual helical tube

The application of latent heat storage systems in waste heat recovery has become a promising solution for energy storage. This study proposes a configuration using dual helical tube, specifically designed for industrial waste heat recovery applications. This study investigates the thermal performance of a horizontal dual helical energy storage unit under natural gravity. It considers various parameters, including helical diameter, the number of helical turns, and eccentricity. When an eccentricity of 5 mm is used, the overall energy storage time is reduced by 30.86 %, and the energy storage density is at its highest (3.11 × 10−4 kW/cm2). Adjusting the outer helical tube to 9 turns produces the highest energy storage efficiency (0.9252). Additionally, the heat transfer characteristics during simultaneous energy storage and release processes have been studied. The results indicate that as the temperature difference or velocity ratio between the heat transfer fluids increases, the liquid fraction at steady state decreases. This decrease in liquid fraction requires a longer time to reach the steady state. When the outer helical tube is filled with the hot fluid and counter flow configuration is adopted, it achieves higher levels of absorption and release power at steady state. The influence of velocity on absorption and release power is more significant than that of temperature difference.

Thermal performance analysis of heat pipe heat exchanger for effective waste heat recovery

The importance of waste heat recovery systems for various industrial processes has been growing steadily, driven by their potential to improve energy efficiency, reduce fuel consumption, and minimize environmental impacts. Heat exchangers are key components in these systems, facilitating the transfer of heat from waste sources to useful media. Among them, heat pipe heat exchangers (HPHX) have been widely employed in industries such as steel and ceramic as an energy-saving measure to cut carbon emissions. Previous studies have mainly focused on experimental analyses of HPHX thermal performance. However, due to the high cost of full-scale thermal tests, there is a lack of research investigating the effect of detailed geometrical and operational variations on HPHX thermal performance. This study addresses the existing gap by conducting a comprehensive conjugate numerical investigation to explore the influence of flow path structure and condenser area on the performance of an air-to-liquid HPHX. We first utilize a full-scale conjugate simulation to propose an optimized HPHX design that enhances both heat transfer rate and effectiveness through the variation of baffle configurations and condenser height. Subsequently, we experimentally validate the proposed design through a full-scale HPHX thermal test. Results revealed that the baffle design significantly improved the heat transfer rate and effectiveness by up to 36.3% and 36.0%, respectively. Conversely, increasing the condenser height by five times enhanced the heat transfer rate by only 3.5%, with the condenser area showing a minor impact owing to the higher heat capacity rate of water compared to air. The outcomes revealed remarkable energy-recovery capabilities, revealing a total thermal energy wastage recovery rate up to 19.7 kW. These findings demonstrate the potential and effectiveness of the proposed HPHX in waste heat recovery applications.

Enhancing the electrical transport properties of two-dimensional semiconductors through interlayer interactions

Thermoelectric materials attract great attention due to promising applications in refrigeration and waste heat recovery.

Investigating the novel thermoelectric properties of magnesium, calcium, and barium divanadate oxides (XV2O6 where X = Mg, Ca, and Ba) for waste heat recovery applications in energy harvesting devices

Investigating the novel thermoelectric properties of magnesium, calcium, and barium divanadate oxides (XV2O6 where X = Mg, Ca, and Ba) for waste heat recovery applications in energy harvesting devices

A PARAMETRIC AND COMPARATIVE STUDY ON BARE-TUBE BANKS AND NEW CAM-SHAPED TUBE BANKS FOR WASTE HEAT RECOVERY APPLICATIONS

The present study numerically examines the effects of tube diameter (12 to 35 mm), arrangement, pitch-to-diameter ratio (1.25 to 2.5), length (300 to 1500 mm), and passage number (1-4 passes) on the thermofluidic characteristics of cross-flow tube bundles. Especially, five new cam-shaped tubes are proposed in comparison with the conventional round tube. The air temperatures at the cold and hot side inlets are kept constant at 25°C and 600°C, respectively. The numerical method is verified by the existing experimental results. The findings show that a cam-shaped tube with an equal diameter (Cam_1818) is a promising tube for tube bundles, which apply in waste heat recovery. Indeed, it can offer the same minimum gap as that of the round tube; however, it improves the total thermal resistance up to about 28% and enhances the heat-transfer rate up to an average of 42.3% compared to that of the round tubes at the same pumping power.

From waste to value: Utilising waste foundry sand in thermal energy storage as a matrix material in composites

Waste foundry sand (WFS) is a by-product of the casting industry, which poses increasing economic and environmental issues due to the costs associated with landfill maintenance and stricter environmental regulations. This study proposes a novel solution for WFS as a material for thermal energy storage. The approach involves blending WFS with NaNO3 and a proprietary additive, X, to fabricate a composite phase change material (CPCM). The CPCM is found to be structurally stable up to 400 °C, and an optimal composition with a mass ratio of NaNO3:WFS:X = 0.6:0.3:0.1 is achieved. This composition yields an energy storage density of 628 ± 27 kJ/kg, and an average thermal conductivity of 1.38 W/mK over the temperature range of 25–400 °C. The CPCM also exhibits good mechanical strength and a low coefficient of thermal expansion compared to NaNO3. Currently, only a small portion of WFS is recycled, most commonly in building applications. The CPCM presented in this study has the potential for medium-to-high temperature heat storage in waste heat recovery applications, offering a sustainable solution for upcycling WFS.

Enhancing thermoelectric performance through acid-treated NbFeSb: A versatile approach for sustainable energy conversion

Drop-casting has emerged as a promising and scalable technique for fabricating thermoelectric generators, suitable for energy harvesting and waste heat recovery applications. This study delves into the potential of thermoelectric drop-casting utilizing acid-treated NbFeSb, a half-Heusler material. The acid treatment notably reduces the particle dimensions of NbFeSb from a micro-scale to a nano-scale, thereby enhancing phonon scattering and diminishing thermal conductivity from 16 to 12 W/mK at room temperature. The formulation of the thermoelectric ink involves ethylene glycol as the solvent and polyvinylpyrrolidone (PVP) as an additive, meticulously optimized to enhance dispersion and rheological attributes. To systematically analyze the performances of the printed films, an investigation was conducted, varying the PVP concentration. Our findings indicate that a 20% PVP content yields the highest power factor, concurrently enhancing the Seebeck coefficient and electrical conductivity, while preserving reduction in thermal conductivity. The ink-printed films of acid-treated NbFeSb exhibited superior thermoelectric performance compared to pristine NbFeSb films, owing to the uniform distribution of nanoparticles and the absence of particle agglomeration. Furthermore, this study successfully fabricates a flexible thermoelectric generator (TEG) using acid-treated NbFeSb ink, demonstrating its potential integration into wearable devices and power generation systems. The TEG attains an open-circuit voltage of 88 mV across a temperature gradient of 40 K, with a peak output power of 8.1 mW. This study highlights the significant impact of thermoelectric drop-casting as an adaptable and efficient approach to enhance the thermoelectric performance of high-thermal-conductivity half-Heusler materials, opening new avenues for sustainable energy conversion technologies.

Performance boost for bismuth telluride thermoelectric generator via barrier layer based on low Young’s modulus and particle sliding

The lack of desirable diffusion barrier layers currently prohibits the long-term stable service of bismuth telluride thermoelectric devices in low-grade waste heat recovery. Here we propose a new design principle of barrier layers beyond the thermal expansion matching criterion. A titanium barrier layer with loose structure is optimized, in which the low Young’s modulus and particle sliding synergistically alleviates interfacial stress, while the TiTe2 reactant enables metallurgical bonding and ohmic contact between the barrier layer and the thermoelectric material, leading to a desirable interface characterized by high-thermostability, high-strength, and low-resistivity. Highly competitive conversion efficiency of 6.2% and power density of 0.51 W cm−2 are achieved for a module with leg length of 2 mm at the hot-side temperature of 523 K, and no degradation is observed following operation for 360 h, a record for stable service at this temperature, paving the way for its application in low-grade waste heat recovery.

Research of the thermal storage properties of thermally conductive carbon fiber-reinforced paraffin/olefin block copolymer composite phase change materials with thermotropic flexibility

This study focuses on the fabrication and evaluation of paraffin (PA)/olefin block copolymer (OBC)/carbon fiber (CF) composite phase change materials (CPCMs) prepared using the melt impregnation process. The resultant PA/OBC/CF CPCMs exhibit superior thermal stability below 200 °C and maintain excellent shape stability at 60 °C. These characteristics are attributed to the alternating soft and hard segments of OBC, wherein the hard segments prevent liquid leakage from PA. The distinct structure of OBC further lends flexibility and recyclability to the PA/OBC/CF CPCMs. The latent heat of these CPCMs ranges from 169.1 to 197.6 J/g. Notably, the CPCMs variant (PA/OBC/CF-1) with 2 wt% CF addition retains 95 % of its initial latent heat even after 100 thermal cycles, thereby demonstrating superior cycling stability. The thermal conductivity of CPCMs with 10 wt% CF is 1.3 times that of pure PA. This significant improvement in thermal conductivity is attributed to the heat conduction pathways provided by the fibrous CF. These results indicate that the fabricated CPCMs offer substantial promise for utilization in low-temperature waste heat recovery applications.

Facile, catalyst-free, and high enthalpy PEG-based phase change composite for use in photothermal conversion and waste heat recovery

The poor shape stability, low thermal storage density, and complex process confronted in fabricating high-performance phase change composites (PCCs) via the chemical cross-linking technology. Herein, PEG-based shape stability PCC (SSPCC) with high enthalpy and good shape stability was obtained using a facile one-pot method without additional catalysts. The reliable three-dimensional cross-linked structure formed by the interaction of epoxy resin and curing agent binds the movement of PEG molecular chains, which simultaneously in coupled with the stronger hydrogen bonding between PEG and cross-linked products to endow the as-prepared SSPCC with excellent shape stability, thermal stability, durability, and high thermal storage density (160.8 J/g). Moreover, the Raman spectra clearly presented the interaction force and phase morphology distribution between PEG and the skeleton structure. SSPCC with the high relative enthalpy efficiency and melt enthalpy can play an essential role in photothermal applications, while the facile manufacturing process free from additional organic solvents or high temperature, highlighting its green and sustainable features. Additionally, the photothermal transport and thermostatic effects of the SSPCCs show great potential for application in waste heat recovery, which can maintain higher temperatures for a long time. Totally, such SSPCC with reliable and distinguished phase change properties ensure a wide range of potential applications, while the easy-to-prepare and low-cost fabrication method provides an inspiring strategy for alternative SSPCC development.

Ferrimagnetic half Heusler alloys for waste heat recovery application - First principle study using different exchange–correlation functionals

ZrMnSi and HfMnSi half Heusler alloys with magnetic ground state are investigated through density functional theory. The different exchange–correlation functionals (GGA, LDA, PBESol and WC) are used to study these alloys. The equilibrium lattice constants and corresponding ground state energies are calculated using these four approximation methods. From GGA functional, the obtained band gap for ZrMnSi is 1.268 eV and HfMnSi is 1.311 eV. The reported alloys are predicted to be half metals from different potentials, where those alloys show semiconductor character in minority spin channel and also exhibit metallic character in majority spin channel. The studied alloys are mechanically stable and ductile in nature. The total magnetic moment of −3μB is obtained in the reported ferrimagnetic alloys. The obtained thermoelectric figure of merit for ZrMnSi and HfMnSi is 0.46 at 1200 K and 0.31 at 1200 K respectively, it shows that these alloys are the potential candidates for waste heat recovery application, and they are also useful for spin flip device application.