Industrial Waste Heat Research Articles

Identification of industrial waste heat potential for district heating systems by pinch-based systematic graphical approach

Identification of industrial waste heat potential for district heating systems by pinch-based systematic graphical approach

Thermochemical technologies for industrial waste heat recovery: A comprehensive review

Thermochemical technologies for industrial waste heat recovery: A comprehensive review

Peltier Power Effect Monitoring as Electrical Energy Generation

Climate change and the depletion of fossil energy resources have driven the search for alternative energy sources that are more environmentally friendly and sustainable. One promising solution is the development of renewable energy systems that optimally utilize natural resources. Thermogeneration technology, which converts temperature differences into electrical energy, has become a focal point in the advancement of renewable energy. The Peltier module, as the core component of this technology, is capable of generating electrical voltage through the thermoelectric effect caused by a temperature difference between its two sides In this study, the Peltier module is used to generate electricity from industrial waste heat or other ambient heat sources. The objective of this research is to identify the energy conversion efficiency and the practical limitations of the Peltier module in renewable energy systems. By employing a device designed to convert heat energy into electrical energy, while also monitoring temperature and voltage, the study evaluates the performance of the Peltier module and introduces a testing methodology to measure the relationship between temperature and voltage. Test results indicate a linear relationship between temperature and generated voltage, with a slope of 0.0375 V/°C, suggesting that the greater the temperature difference, the higher the voltage produced. This research is expected to contribute to the development of Peltier-based renewable energy technologies and to improve the efficiency of waste heat utilization in supporting more environmentally sustainable energy practices.

Coupling high-temperature electrolysis and industrial waste heat for on-site green hydrogen production: energy, economic and environmental analysis

Coupling high-temperature electrolysis and industrial waste heat for on-site green hydrogen production: energy, economic and environmental analysis

50 kWe R1336mzz(Z) ORC power generation system for industrial waste heat recovery: System design and commissioning test results

50 kWe R1336mzz(Z) ORC power generation system for industrial waste heat recovery: System design and commissioning test results

Optimizing Hydrogen Liquefaction Efficiency Through Waste Heat Recovery: A Comparative Study of Three Process Configurations

Hydrogen (H2) liquefaction is an energy-intensive process, and improving its efficiency is critical for large-scale deployment in H2 infrastructure. Industrial waste heat recovery contributes to energy savings and environmental improvements in liquid H2 processes. This study proposes a comparative framework for industrial waste heat recovery in H2 liquefaction systems by examining three recovery cycles, including an ammonia–water absorption refrigeration (ABR) unit, a diffusion absorption refrigeration (DAR) process, and a combined organic Rankine/Kalina plant. All scenarios incorporate 2 MW of industrial waste heat to improve precooling and reduce the external power demand. The simulations were conducted using Aspen HYSYS (V10) in combination with an m-file code in MATLAB (R2022b) programming to model each configuration under consistent operating conditions. Detailed energy and exergy analyses are performed to assess performance. Among the three scenarios, the ORC/Kalina-based system achieves the lowest specific power consumption (4.306 kWh/kg LH2) and the highest exergy efficiency in the precooling unit (70.84%), making it the most energy-efficient solution. Although the DAR-based system shows slightly lower performance, the ABR-based system achieves the highest exergy efficiency of 52.47%, despite its reduced energy efficiency. By comparing three innovative configurations using the same industrial waste heat input, this work provides a valuable tool for selecting the most suitable design based on either energy performance or thermodynamic efficiency. The proposed methodology can serve as a foundation for future system optimization and scale-up.

A Comprehensive Review of Thermoelectric Generators from Micropower Supply to Kilowatt System

Review A Comprehensive Review of Thermoelectric Generators from Micropower Supply to Kilowatt System Shuo Yang, Hao Chen and Ding Luo * Shaanxi Key Laboratory of New Transportation Energy and Automotive Energy Saving, Chang’an University, Xi’an 710064, China * Correspondence: Ding_L@outlook.com Received: 14 March 2025; Revised: 9 April 2025; Accepted: 10 April 2025; Published: 22 April 2025 Abstract: Energy crisis and carbon emissions are two increasingly prominent issues in our society. As one of the clean energy sources, thermoelectric power generation is a promising alternative energy technology to convert heat into electricity. As long as there is a heat source, thermoelectric generators can provide electricity for watches, sensors, electronics, spacecraft, etc., and can also be used to recover waste heat, such as automobile exhaust heat, industrial waste heat, ship waste heat, etc. This study proposes a novel classification paradigm based on power output (microwatt, 1 W–1 kW, >1 kW), systematically revealing the technological characteristics at each power level: the microwatt level relies on flexible materials and compatibility with human body heat, while the kilowatt level requires the integration of high-temperature materials and optimized thermal management. The study also demonstrates that performance can be significantly enhanced through asymmetric geometric designs and non-equilibrium synthesis processes. This work provides a comprehensive design framework, from material innovation to large-scale integration, for next-generation thermoelectric systems, addressing the theoretical gap in techno-economic analysis.

Optimization of nano-finned enclosure-shaped latent heat thermal energy storage units using CFD, RSM, and enhanced hill climbing algorithm

Thermal energy storage plays a critical role in improving energy efficiency and sustainability, particularly in solar energy systems, industrial waste heat recovery, and building temperature regulation. However, traditional latent heat thermal energy storage (LHTES) systems face significant challenges due to the low thermal conductivity of phase change materials (PCMs), leading to prolonged charging/discharging times and reduced efficiency. To address these limitations, this study presents a framework for optimizing nano-finned enclosure-shaped LHTES units that incorporate nano-enhanced phase change materials (NePCMs) and fins. The research employs a novel hybrid approach that integrates computational fluid dynamics (CFD) simulations, response surface methodology (RSM), and an enhanced hill climbing (EHC) optimization technique to explore the complex interplay between fin geometry and nanomaterial characteristics. The influence of key design variables—including three fin geometry parameters (number, length, volume), nanomaterial concentration, and eight nanomaterials (metal, oxide, and carbon-based)—is analyzed to optimize phase change time and total stored energy. Results demonstrate that reduced sixth-degree and reduced quartic polynomial models, developed through RSM, provide high accuracy in predicting total stored energy and melting time, respectively. While the incorporation of nanomaterials generally reduces total stored energy due to their lower latent heat, carbon-based nanomaterials (GNPs, MWCNTs) offer an optimal trade-off, achieving faster melting times with minimal energy storage loss. Among the studied parameters, fin volume fraction plays a more dominant role in determining energy storage capacity compared to nanomaterial volume fraction. The optimal design configuration varies based on the priority assigned to melting time or stored energy. In a melting-time-focused scenario, the optimized unit achieves 63.03 kJ of stored energy with a melting time of 91.76 s. When prioritizing energy storage, the stored energy increases to 66.15 kJ, but the melting time extends to 222.3 s. A balanced optimization scenario yields 64.67 kJ of stored energy and a melting time of 137.4 s. These findings provide valuable insights into the design and optimization of advanced LHTES units for enhanced thermal energy management.

Sustainable Hydrogen Production with Negative Carbon Emission Through Thermochemical Conversion of Biogas/Biomethane

Biogas (primarily biomethane), as a carbon-neutral renewable energy source, holds great potential to replace fossil fuels for sustainable hydrogen production. Conventional biogas reforming systems adopt strategies similar to industrial natural gas reforming, posing challenges such as high temperatures, high energy consumption, and high system complexity. In this study, we propose a novel multi-product sequential separation-enhanced reforming method for biogas-derived hydrogen production, which achieves high H2 yield and CO2 capture under mid-temperature conditions. The effects of reaction temperature, steam-to-methane ratio, and CO2/CH4 molar ratio on key performance metrics including biomethane conversion and hydrogen production are investigated. At a moderate reforming temperature of 425 °C and pressure of 0.1 MPa, the conversion rate of CH4 in biogas reaches 97.1%, the high-purity hydrogen production attains 2.15 mol-H2/mol-feed, and the hydrogen yield is 90.1%. Additionally, the first-law energy conversion efficiency from biogas to hydrogen reaches 65.6%, which is 11 percentage points higher than that of conventional biogas reforming methods. The yield of captured CO2 reaches 1.88 kg-CO2/m3-feed, effectively achieving near-complete recovery of green CO2 from biogas. The mild reaction conditions allow for a flexible integration with industrial waste heat or a wide selection of other renewable energy sources (e.g., solar heat), facilitating distributed and carbon-negative hydrogen production.

An efficient thermal water pump for electricity-free recovery of industrial waste heat

An efficient thermal water pump for electricity-free recovery of industrial waste heat

Thermodynamic architecture for steam generation using heat pumps system valorizing industrial waste heat

Thermodynamic architecture for steam generation using heat pumps system valorizing industrial waste heat

Prediction of Heat Output Power in Open-Loop Adsorption Heat Pump Systems Using LightGBM

Abstract This paper focuses on the prediction of heat output power of an “open-loop” adsorption heat pump system, aiming to achieve intelligent management of industrial waste heat recovery through machine learning techniques. Based on the actual data of an adsorption heat pump system, the study identifies key factors affecting heat load, such as flue gas volume and energy supply methods, and constructs a standard database. The LightGBM algorithm and GridSearchCV were employed for model parameter optimization to build a prediction model. The model achieved an RMSE of 7.45 kW, CVRMSE of 12.61%, and accuracy of 87.80%, demonstrating high prediction accuracy over a 15-day prediction duration. This research not only provides technical support for the energy-saving transformation of “open-loop” adsorption heat pump systems but also offers new ideas and methods for the efficient utilization of industrial waste heat.

Enhanced energy storage density in thermal energy storage systems simultaneously heated with solar radiation and industrial waste heat

Enhanced energy storage density in thermal energy storage systems simultaneously heated with solar radiation and industrial waste heat

Modeling of an Ammonia/Water Absorption Heat Transformer to upgrade low-temperature industrial waste heat both at machine scale and at local scale inside the falling film absorber

Modeling of an Ammonia/Water Absorption Heat Transformer to upgrade low-temperature industrial waste heat both at machine scale and at local scale inside the falling film absorber

Addressing industrial waste heat supply variability with Organic Rankine Cycle systems incorporating thermal energy storage

Addressing industrial waste heat supply variability with Organic Rankine Cycle systems incorporating thermal energy storage

Novel Cs2AuIMIIIF6 (M = As, Sb) double halide perovskites: sunlight and industrial waste heat management device applications.

The upcoming lead-free double halide perovskites are sustainable alternatives to lead perovskites in renewable energy technologies. This study conducted a comprehensive investigation into the structural, electronic, optical, and thermoelectric properties of novel Cs2AuIMIIIF6 (M = As, Sb) double halide perovskites using a density functional theory-based approach. The tolerance factors and negative formation energies, as well as analysis of phonon dispersion, confirm structural and dynamic stability. There are favorable values of elastic coefficients and Pugh's and Poisson's ratios, which prove that there is mechanical stability, and ductility is also proven. The compounds show indirect band gaps of 1.144 eV (Cs2AuAsF6) and 1.746 eV (Cs2AuSbF6), which fall within the range of absorption of visible light. Optical analysis reveals high absorption coefficients, thereby making this material suitable for photovoltaic applications. Thermoelectric properties show moderate ZT values of approximately 0.64 and 0.61 at 500 K, which signify their application for waste heat recovery. Thus, the currently presented work proves the potential of Cs2AuIMIIIF6 (M = As, Sb) perovskites as effective materials from an environmental perspective for energy harvesting devices.

Study on thermophysical properties and corrosion of low melting point chloride phase change heat storage materials

Abstract Energy transition is the key to solving environmental problems in the energy sector, and the development and utilization of clean energy and industrial energy conservation are more effective solutions. Among them, the application of the energy storage system is an important link, and the performance of the heat storage molten salt will directly affect the conversion and utilization of the entire energy heat exchange system. In this paper, a kind of NaCl-KCl-FeCl3 mixed chloride molten salt with a mass ratio of 35:10:55 was prepared by the grinding method, using synchronous thermal analyzer (STA), transient plane heat source method, microscopic morphology analysis, and corrosion dynamic curve to characterize the melting point, thermogravimetry, thermal conductivity, and corrosion properties of the material. It was found that the melting point of the ternary chloride is 140.4°C, the molten salt can work stably at high temperatures, and its thermal conductivity increases with the increase in temperature. The 316L steel sheet is mixed with NaCl-KCl-FeCl3 at 350°C among the chloride molten salts, which has better corrosion resistance. The material has the advantages of low melting point, relatively stable under high temperatures, low viscosity, and low corrosiveness to 316L steel sheets, and is expected to be used in fields such as building energy saving and industrial waste heat utilization.

Introduction to ORC–VCC Systems: A Review

The increasing demand for sustainable energy solutions has spurred significant interest in cogeneration technologies. This study introduces a novel integrated organic Rankine cycle (ORC) and vapor compression cycle (VCC) system, specifically designed to enhance energy efficiency and reduce greenhouse gas emissions in industrial applications and district heating systems. The key innovation lies in the development of an advanced coupling mechanism that seamlessly connects the ORC and VCC, enabling more efficient utilization of low-grade heat sources. By optimizing working fluid selection and implementing a shared shaft connection between the ORC turbine and VCC compressor, the system achieves dual functionality—simultaneous electricity generation and cooling—with higher efficiency than conventional methods. Thermodynamic analyses and experimental results demonstrate that the proposed ORC–VCC system can significantly reduce operational costs and decrease reliance on fossil fuels by leveraging renewable energy sources and industrial waste heat. Additionally, the study addresses integration challenges by introducing specialized components and a modular design approach that simplifies installation and maintenance. This innovative system not only enhances performance but also offers scalability for various industrial applications. By providing a detailed evaluation of the ORC–VCC integration and its practical implications, this work underscores the system’s potential to contribute substantially to a sustainable energy transition. The findings offer valuable insights for future research and development, highlighting pathways to overcome existing barriers in cogeneration technologies.

Energy storage materials for phase change heat devices recovering industrial waste heat for heating purposes

Energy storage materials for phase change heat devices recovering industrial waste heat for heating purposes

Research on Industrial Waste Heat Recovery and Multi-energy Coupling System

Research on Industrial Waste Heat Recovery and Multi-energy Coupling System