Industrial Waste Heat Research Articles

Experimental study on an improved direct-contact thermal energy storage container

Direct-contact thermal energy storage (TES) systems characterized by high heat density and rapid heat transfer rates have been exploited for the collection of industrial waste or surplus heat for subsequent utilization. In order to address blockage issue at the initial stage of charging process, an improved direct-contact TES container was developed by incorporating a double-pipe structure at both the inlet and outlet. Within the container, a U-shaped tube serving as the inner tube was concentrically positioned from the inlet to the outlet. Erythritol was selected as the phase change material (PCM), while heat transfer oil (HTO) functioned as the heat transfer medium during experimentation. During the charging process, hot HTO initially flowed through the U-shaped tube, establishing an indirect contact with the PCM. The high thermal conductivity of the U-shaped tube wall expedited the formation of a flow channel within the solid PCM. The duration of forming flow channel was 6 to 13 min. In the discharging phase, the liquid PCM was segregated into convection and conduction zones. The indirect-contact TES experiments were also conducted in the same container. Comparison between indirect-contact and direct-contact TES were analysed from the aspects of phase change behavior, charging and discharging time with the identical container structure and theoretical heat capacity. Results indicated that the direct-contact TES container exhibited superior heat storage and release rates, with the direct-contact discharging time being approximately a quarter of the indirect-contact duration. The phase change behavior of the PCM was notably influenced by the movement of HTO within the direct-contact storage container.

Driving industrial symbiosis: Evaluating policy intervention effects on waste heat utilization in local district heating networks

This study aims to quantitatively assess the required policy support level to ensure economic viability for all stakeholders in the context of using industrial waste heat as source of local district heating (DH). Additionally, the research explores the potential of industrial symbiosis to support district-level energy transition in the context of Positive Energy Districts and Smart Cities. The proposed approach combines energy modelling tools, namely the Multi Energy System Simulator (MESS) model and financial concepts (i.e. Cash Flow Analysis, Net Present Value Evaluation) typical of industry’s project evaluation. It is then tested in the area of Bolzano, Italy. The study examines various policy scenarios, including financial incentives and the involvement of district heating operators (DHOs). Initial findings indicate that district heating offers significant cost advantages (up to –23%) over electrified systems. However, industries face challenges meeting standard payback periods without policy intervention in the context of projects using waste heat as a source of DH. A combined scenario involving DHOs handling connection costs with a 60% incentive and industries receiving a 15% Feed-In Premium shows promising results in achieving economic feasibility. The results underscore the critical role of policy support in overcoming barriers. Consequently, it is possible to strengthen cooperation between industries and districts fostering local energy transition. Nonetheless, the achievement of positive energy balance requires a stronger presence of RES particularly on the electricity side. The study highlights the broader implications for similar projects in other regions and the essential role of policy interventions in facilitating such industrial symbiosis.

Optimization of material properties and performance of flexible thermoelectric generators with/without graphene

With the advancement of energy harvesting methods, the power level consumed by electronic circuits and sensors has been reduced so that self-sufficiency in power can be achieved, and the use of flexible thermoelectric generators to supply electrical energy is one of these methods. In this study, the manufacture of flexible thermoelectric generators is successfully developed and verified using a numerical method. The process follows the sandwich method of the conventional thermoelectric module and utilizes two different elastomers (polydimethylsiloxane and Eco-Flex) and thin copper sheets. Among the nine cases designed by the Taguchi method, the maximum tensile strength of the elastomer is 0.967 MPa, stemming from the operation conditions of 6 min stirring time, 85 °C heating temperature, and 3 h heating time. This strength is substantially higher than those of the other eight cases. The open-circuit voltage of the manufactured flexible thermoelectric generator with an internal resistance of 1.5 Ω is 0.011 V. The output power under a temperature difference of 75 °C is 11 μW. After blending graphene into polydimethylsiloxane, the elastomer’s thermal conductivity at 370 K rises by 9.6 folds. This results in the output power being lifted to 0.0515 W (75 °C temperature difference), accounting for an amplification of 4,681 times. Numerical simulations are also performed to aid in figuring out the detailed performance of the flexible thermoelectric generator. The errors between numerical simulations and experiments are between 4.6 % and 5.2 %, showing the reliability of the numerical predictions. The fabricated flexible thermoelectric generators can be practically used for green power generation by harvesting industrial low-temperature waste heat and biothermal energy, potentially driving sensors on industrial devices, the human body, and animals.

METHODS OF RECOVERING WASTE HEAT FROM NATURAL GAS SCREW COMPRESSORS SYSTEMS

Industrial waste heat recovery (WHR) captures excess thermal energy from industrial processes, offering significant economic, environmental, and operational benefits. Economically, WHR reduces fuel consumption and energy costs, improving equipment efficiency and competitiveness. Environmentally, it lowers greenhouse gas emissions and cuts fossil fuel reliance, aiding sustainability and compliance. Specifically, in natural gas compression, significant waste heat is generated. Recovering this heat from screw compressors, whether driven by electric motors or internal combustion engines, enhances energy efficiency. This paper discusses methods and technologies for effective waste heat recovery, focusing on thermodynamic principles

1-Dimensional metal Nitride-Supported platinum nanoclusters for Low-Temperature hydrogen production from formic acid

Formic acid is widely recognized as a suitable liquid hydrogen carrier for linking renewable energies toward various economic sectors. Designing efficient and stable heterogeneous catalysts for low-temperature hydrogen generation from formic acid is vital for this topic. In this study, a rational hierarchical architecture is explored by assembling Pt nanoclusters with 1-dimensional (1D) GaN nanowires. The catalytic architecture describes a considerable hydrogen production activity of 54.89 mmol·gcat−1·h−1 with a nearly 100 % selectivity and a turnover frequency (TOFPt) of 505.7 h−1 under near ambient condition, enables the achievement of a high turnover number of 306,981 mol H2 per mole Pt over 200 h of long-term operation. Through comprehensive mechanistic studies, it is unraveled that the synergistic effect between Pt nanoclusters and GaN significantly reduces the energy barrier for the formation of the key HCOO* intermediate from formic acid dehydrogenation whereas significantly increase the energy barrier of HCOOH → HCO* + *OH. It thus simultaneously contributes to improving the activity and selectivity of formic acid decomposition toward H2. This study proposes a promising strategy for hydrogen generation from formic acid at low temperatures, which is critical for achieving carbon neutrality by coordinating industrial waste heat with renewable energies via liquid hydrogen carriers.

Nanofiber aerogel with layered array with structure coupled photothermal/magnetothermal effect for continuous seawater desalination

The solar evaporation is susceptible to intermittent solar irradiation as well as salt crystallization deposition on the surface severely limits the evaporation efficiency. In this work, subject to inspiration of the transpiration, groove array structure and antifouling performance of banana leaves, a multifunctional photothermal/ magnetothermal coupled three-dimensional(3D) aerogel evaporator with layer-by-layer array structure was prepared by blow-spun technology which can achieve mass produced. The unique super hydrophilic vertical array structure has multi-scale high-efficiency water transport channels and the SnSe-Fe3O4 evaporation layer realizes super hydrophobic self-cleaning and excellent photothermal and magnetothermal conversion performance, which can achieve all-weather seawater desalination. The vertical array structures facilitate the reflection and refraction of light and promote the seawater convection and salt crystals absorption coupling. It could improve the photothermal conversion efficiency and salt resistance of the evaporator. Which resulted in an evaporation rate of 2.53 kg m−2h−1 under 1 sun, with solar energy conversion efficiency of 105 % and the evaporation rate is about 4.54 kg m−2h−1 at a magnetic field. Furthermore, it could purify organic pollutants in industrial wastewater and use waste heat to generate electricity. This evaporator provides a new economical and environmentally friendly solution for seawater desalination and sewage treatment.

Research on the Performance of Thermoelectric Self-Powered Systems for Wireless Sensor Based on Industrial Waste Heat.

The issue of energy supply for wireless sensors is becoming increasingly severe with the advancement of the Fourth Industrial Revolution. Thus, this paper proposed a thermoelectric self-powered wireless sensor that can harvest industrial waste heat for self-powered operations. The results show that this self-powered wireless sensor can operate stably under the data transmission cycle of 39.38 s when the heat source temperature is 70 °C. Only 19.57% of electricity generated by a thermoelectric power generation system (TPGS) is available for use. Before this, the power consumption of this wireless sensor had been accurately measured, which is 326 mW in 0.08 s active mode and 5.45 μW in dormant mode. Then, the verified simulation model was established and used to investigate the generation performance of the TPGS under the Dirichlet, Neumann, and Robin boundary conditions. The minimum demand for a heat source is cleared for various data transmission cycles of wireless sensors. Low-temperature industrial waste heat is enough to drive the wireless sensor with a data transmission cycle of 30 s. Subsequently, the economic benefit of the thermoelectric self-powered system was also analyzed. The cost of one thermoelectric self-powered system is EUR 9.1, only 42% of the high-performance battery cost. Finally, the SEPIC converter model was established to conduct MPPT optimization for the TEG module and the output power can increase by up to approximately 47%. This thermoelectric self-powered wireless sensor can accelerate the process of achieving energy independence for wireless sensors and promote the Fourth Industrial Revolution.

Experimental research on chemisorption energy storage performance for industrial waste heat recovery and conversion

This study investigates a solid chemisorption energy storage system utilizing a multi-component chloride salt composite adsorbent with a mass ratio of NH4Cl, CaCl2, MnCl2, and expanded natural graphite treated with sulfuric acid (ENG-TSA). The system features a shell-and-tube heat exchanger and analyzes refrigeration and heat storage performance under varying industrial low-temperature waste heat (60–110 °C) conditions, with condensation and evaporation temperatures of 0–25 °C and discharging temperatures of 40–60 °C. The results indicate that the multi-salt composite adsorbent reduces hysteresis between adsorption and desorption stages. The highest coefficient of performance (COP) and specific cooling power (SCP) were 0.461 and 328 W/kg, respectively, at an evaporation temperature of 25 °C and a charging temperature of 110 °C. Excessively long cycle times negatively affect system efficiency, with optimal performance achieved at a 40-min cycle. The findings highlight the system's effectiveness for industrial low-grade waste heat recovery, providing a solid foundation for future reactor design and material selection.

Off-design performance optimization for steam-water dual heat source ORC systems

High-pressure steam and hot water often coexist as industrial waste heat. In this study, dual loop and single loop ORC systems are designed for 700 kPa, 4.1 kg/s steam, and 90 ℃, 122.36 kg/s hot water conditions to study the off-design performance when steam or hot water conditions change. To maximize net output power, we employ a particle swarm optimization algorithm to optimize the evaporation and condensation temperatures. The results show that within the specified hot water conditions, the evaporation and condensation temperatures of D-ORC's low-pressure loop and S-ORC increase with rising hot water inlet temperature and flow rate. The S-ORC demonstrates a higher net output power growth rate as hot water flow rate and temperature rise. Under specific steam conditions, when the steam outlet is in a gas-liquid two-phase state, D-ORC's maximum net output power is 1.7 % higher than that of the S-ORC, with little variation in optimal evaporation and condensation temperatures with respect to steam inlet pressure. At a 3.5 kg/s steam flow rate, the D-ORC's high-pressure loop becomes ineffective, whereas S-ORC efficiently adjusts heat exchange capacity under diverse steam-water conditions, Consequently, the D-ORC's average net output power is 34.2 % lower than that of the S-ORC.

Dimethyl carbonate/methanol separation by azeotropic distillation with water: An alternative process driven by low-pressure steam

This study reported a conceptual design of dimethyl carbonate/methanol (DMC/MET) separation via an azeotropic distillation (AD) process with water as the entrainer. Water can form a minimum azeotrope with DMC, stripping DMC from MET via a distillation column. Meanwhile, the liquid–liquid equilibrium can lift the DMC fraction from the azeotropic composition to a much higher level with a decanter. It enables the subsequent distillation column to produce pure DMC. The techno-economic analysis after process optimization demonstrated that the total annualized cost (TAC) of the AD process is 13.8 % lower than the conventional extractive distillation (ED) process. Subsequently, heat integration and double-effect distillation were introduced to further increase the energy efficiency. The improved AD process is also superior to the improved ED process (31.7 % energy cost and 4.1 % TAC saved). Moreover, the moderate temperature of the reboilers of the AD process with water as the entrainer further elevates its superiority since industrial waste heat can be applied in this case.

Exploration of new function for thermal energy storage: Temperature stabilizer

Thermal energy storage (TES) is a technology that stores thermal energy by heating or cooling a storage medium so that the stored energy can be used when needed. TES is usually used in greenhouse heating, centralized solar power, and industrial waste heat recovery to improve the efficiency of energy utilization. This article explores a new application of TES, which relies on its constant outlet temperature to provide stable working conditions for other components. A simulation consisting of 10 cycles with a total length of 100 h is designed. Each cycle contains 5 h of discharge and 5 h of charge, achieved by adjusting the inlet temperature. Rock and NaNO3 are selected as materials for sensible and latent heat storage. This paper discusses the temperature distribution and thermal storage capacity of TES under alternating inlet temperature. The results indicate that the outlet temperature of sensible heat storage will fluctuate and the maximum amplitude is 4.56 K. For latent heat storage, the outlet temperature is constant, and fluid temperature and liquid phase ratio distribution do not change with the number of cycles. There is a significant temperature difference between fluid and solid in phase transition stage, with a maximum value of 10.72 K. Mathematical relationship between latent heat storage parameters and the minimum length of TES is obtained.

Optimization of methane partial oxidation for hydrogen production with local free space addition: An efficient combination of porous media reactor and thermoelectric conversion system

Thermoelectric technology plays a pivotal role in the efficient conversion and utilization of exhaust heat. Abundant waste heat resources are present in the tail gas of hydrogen production, significantly influenced by combustion characteristics. To investigate the impact of combustion performance on hydrogen yield and power output, an efficient porous media reactor was designed and integrated with a thermoelectric conversion system. The combustion characteristics of a thermoelectric system incorporating unsteady porous media were examined. Furthermore, the effects of the porous media’s structural parameters on temperature distribution, gas concentration, and power generation were analyzed under various operating conditions. The results revealed that radial free space structures exhibited higher hydrogen and methane conversion efficiencies compared to axial free space structures at verge and toroidal positions. However, the height of the radial free space exerted a more substantial influence on temperature distribution and gas production than the size of the free space itself. At a height of 39 mm, hydrogen concentration and yield reached their peak values of 14.5 % and 53 %, respectively. Combustion was found to significantly impact power generation, with a downward shift of the flame resulting in decreased power output. The inlet velocity was observed to affect the thermoelectric generator power, with a maximum steady-state power of 3.95 W achieved at a velocity of 16 cm/s. These findings provide practical guidance for the efficient utilization of industrial waste heat.

Flow-induced vibration of turbo-expander impellers for industrial waste heat recovery: An analysis based on two-way fluid structure interaction

In the effort to conserve energy and reduce emissions, waste heat recovery for power generation offers a significant advantage by enabling energy recycling. The turbo-expander, a critical component within expansion power generation systems, plays a pivotal role. However, flow during various operation can generate vibrations that negatively affect operational efficiency and trigger safety hazards. Therefore, studying the flow-induced vibration of the turbo-expander is of significant value. We apply computational fluid dynamics (CFD) and transient structural mechanics to examine the flow-induced vibration characteristics of the turbo-expander influenced by stator-rotor interaction using a two-way fluid structure interaction (FSI) strategy. The flow field modeling and calculation approach discussed here is validated through actual operating data from a prototype. Subsequent stages involve coupling the steady-state flow field with the structural field and performing pre-stress modal analysis on the impeller. In the end, we integrate flow-induced excitation from flow field calculations with the transient structural field to calculate the impeller’s flow-induced vibration at the expansion end of the turbo-expander. Our analysis reveals that guide vane frequency (3267 Hz), its harmonic frequencies, and pre-stress modal frequency (1465 Hz) prominently manifest in pressure pulsation and the dynamic response of the turbo-expander impeller under the influence of stator-rotor interaction.

Experimental investigation of a small-scale reversible high-temperature heat pump − organic Rankine cycle system for industrial waste heat recovery

Innovative technologies are required to mitigate the challenges of climate change. A reversible high-temperature heat pump (HTHP) − organic Rankine cycle (ORC) system can be used for effective utilisation of industrial waste heat in the lower temperature band <100 °C. The system can provide useful process heat for industrial processes by operating in HTHP mode or generating power in ORC mode. This paper presents the experimental investigation of the reversible system in both HTHP and ORC modes. A single scroll unit was selected for the compressor (HTHP) and expander (ORC) roles, keeping the system compact. A HCFO refrigerant, R1233zd(E), with a low GWP value, was chosen as the working fluid for both operating modes. When operated in HTHP mode, a maximum compressor overall isentropic efficiency of 73.4 % and a COPmech of 4.8 (ΔTlift,rside = 41 K, Tsf,ev,in = 60 °C) was obtained. In ORC mode, the maximum net power output was 512.4 W (Tsf,ev,in = 90 °C, rp = 2.3), overall cycle efficiency was 3.01 %, and overall isentropic efficiency of the expander was 54.6 %. The technical limitations encountered, and solutions put in place during the experimental testing campaign are discussed in detail.

Thermodynamic Optimization of a Combined Cooling and Power System Utilizing Industrial Waste Heat

Thermodynamic Optimization of a Combined Cooling and Power System Utilizing Industrial Waste Heat

Numerical Study of an Energy Storage Container with a Flat Plate Phase Change Unit Characterized by an S-Shaped Flow Channel

China’s rapid economic development and rising energy consumption have led to significant challenges in energy supply and demand. While wind and solar energy are clean alternatives, they do not always align with the varying energy needs across different times and regions. Concurrently, China produces substantial amounts of industrial waste heat annually. Effective recycling of this waste heat could substantially mitigate energy supply and demand issues. The Mobile Thermal Energy Storage (M-TES) system is a key solution to address these challenges, as it helps manage the uneven distribution of energy over time and space. This article establishes a packaged M-TES based on a plate-type phase change unit. Based on different placement methods of the plate-type phase change unit, different inlet temperatures and phase change temperature differences, and different inlet and outlet directions, the complete charging and discharging process of the packaged phase change thermal storage system was simulated using ANSYS FLUENT 2022 R1 software. The results showed that during the heating process of the entire system, the horizontal placement of the plate-type phase change unit and the inlet and outlet methods of the heat transfer fluid (HTF) significantly improved the heating effect of the system, increasing it by 15.9%. Increasing the temperature difference between the inlet temperature of the heat transfer fluid and the melting temperature of the phase change material (PCM) from 4 K to 19 K can increase the melting rate of PCM by approximately 54.9%

Advanced thermoelectric performance of a textured ceramic composite: Encapsulation of NaxCoO2 into a triple‐phase matrix

AbstractSodium cobaltite (NaxCoO2) is one of the most renowned and thermoelectrically promising p‐type cobalt oxide materials, showing exceptional performance in this domain. Nonetheless, its thermal instability in air renders it unsuitable for high‐temperature applications such as energy harvesting from industrial waste heat. To utilize the beneficial properties of NaxCoO2, microscale NaxCoO2 template particles of significantly larger size were effectively embedded within a thermally stable Ca3Co4−yO9+δ–NaxCoO2–Bi2Ca2Co2O9 triple‐phase matrix. This approach additionally aimed to enhance the texture and boost the thermoelectric performance of the ceramic composite. Highly textured p‐type ceramic composites were fabricated via uniaxial cold‐pressing and pressureless sintering in air. The unique hexagonal NaxCoO2 template particles, produced through molten‐flux synthesis, allowed precise control over their shape and dimensions, while the matrix was synthesized via a sol–gel synthesis. The integrated NaxCoO2 particles of the textured composite exhibited increased thermal stability, showing no sign of decomposition at 1173 K in air, whereas the sole template particles decomposed at 1073 K during sintering. A 20 wt% template particle content in the textured composites resulted in a remarkably high and nearly temperature‐independent power factor of 8.8 µW cm−1 K2, corresponding to an improvement of 13% compared to that of the pure matrix material.

Load prediction and energy efficiency improvement of steelmaking waste heat centralized heating systems under mild climate in China

HVAC energy consumption accounts for more than 50 % of the total building energy consumption globally and using industrial waste heat has huge potential for energy savings in central heating systems. Under the background of the use of renewable energy and the gradual rise of central heating in mild climate areas in China, it is worth paying attention to the problem of excessive energy consumption caused by the inaccurate load prediction of central heating systems when the ambient temperature changes. L City, Guizhou Province, is the first city with central heating in southern China. The temperature variation during winter in L City can manifest the climatic characteristics of a mild region. Therefore, based on the operational data of the steel waste heat central heating system in L City, Guizhou Province, China, during the heating season of 2022–2023, this study discusses the load prediction and energy-saving optimization strategy of the central heating system in a mild climate. SketchUp was used to conduct 3D modeling of the actual buildings in the heating area and TRNSYS was imported to simulate the system load. The difference between the heating load forecast and the actual operating data was analyzed in detail by using the calculation results. Based on the simulation results, the waste heat utilization strategy was adjusted and the influence of different heating schemes on the pump energy consumption under different load demands was discussed. The results reveal that based on the temperature change rule, the accurate load prediction can lead to a 28.64 % saving of the system energy. Concerning system energy consumption, by adjusting the water flow and choosing the large and small pump system, the energy saving amounts to 39.48 % compared with the traditional single-pump system. Meanwhile, in the transition season when the heating demand is less than 20 MW, the adjusted heating scheme can achieve a 38.5 % saving based on the constant flow scheme and a 5.4 % saving based on the constant temperature difference scheme. This article provides a scientific energy-saving solution for heating in mild climates using industrial waste heat, not only reducing energy consumption but also providing an important reference for the energy-saving renovation of heating systems in similar areas.

Maximizing thermal performance in triangular honeycomb thermochemical reactors: Structural and operating parameter studies

Using thermochemical energy storage methods to store energy is increasingly vital for boosting the share of renewable energy in consumption within buildings and industries. This entails harnessing off-peak excess renewable energy, such as electricity or waste heat energy, for storage purposes. While previous research emphasizes the importance of improving reactor performance, comprehensive analysis of the new honeycomb reactor designs is lack. Innovative advancements in maximizing thermal performance within triangular honeycomb reactors are elucidated in this study. This study employs a validated 3-D model to explore the effects of these parameters on heat and mass transfer within a triangular honeycomb reactor. By investigating structural and operational parameters, a novel equilibrium is achieved, amplifying heat exchange efficiency and channeling thermal energy with unprecedented precision. Through a rigorous examination of reactor air velocity distribution, air temperature lift, and outlet air absolute humidity, this research unveils pivotal insights into enhancing reactor efficacy. Notably, the study identifies that increasing the channel thickness by 1.2 times, resulting in energy storage density of 463 kJ/kg. This innovation positions triangular honeycomb reactors at the forefront of sustainable energy management, offering a potential solution for decarbonization such as storing industrial waste heat and harnessing surplus off-peak electricity in buildings.

Theoretical investigation of the post-combustion recovery process in cobalt-based zero-carbon fuels

The application of Co-based recyclable zero-carbon fuels, utilizing oxygen both as a heat transfer fluid and reactant, has gained significant attention as a potential solution to address the intermittency challenges associated with zero-carbon renewable sources. However, the widespread adoption of these fuels faces obstacles, particularly when industrial waste heat deviates from the optimal operational temperature range of 900–1000 °C. Despite efforts to modify operation temperatures, the underlying reaction mechanism remains unclear. To elucidate the crucial factors influencing the recovery process of Co-based recyclable zero-carbon fuels, the density functional theory (DFT) method was employed to analyze the deoxygenation process of the spinel structure. This is essential as the recovery and combustion process involve the dissociation and reconstruction of crystal structures. In this study, the desorption steps of oxygen were studied separately. After the complete desorption of the first layer atoms from the slab surface, the second layer is exposed. To ensure structure stability, the surface undergoes reconstruction. The analysis revealed that the concentration of oxygen vacancy of the same type on the slab surface significantly impacts the energy barrier of deoxygenation, particularly in the initial two stages. This finding is further supported by examining the deoxygenation process in Co2MO4 (M=Mn, Mg, Ni, and Cu) fuels, as reported in previous studies. Notably, the surface energy emerged as a key parameter for these Co-based spinel structure fuels. Modifying the surface energy, by lowering it, was identified to enhance the structural stability to increase the recovery temperature. Conversely, improving the surface energy will decrease the stability and lower the recovery temperature. Understanding and manipulating these factors, as proposed in this study, offer avenues for tailoring Co-based recyclable zero-carbon fuels for various industrial processes. This work serves as a crucial guide for further research and development in this field, potentially unlocking new possibilities to broaden the operation temperature range and enhance the performance of these fuels.