Low-grade Heat Recovery Research Articles

A novel optimization framework integrating multiple initialization, automatic topologization and MINLP reduction to accelerate large-scale heat exchanger network synthesis

Ensuring the solution feasibility and achieving an acceptable solution time for the non-deterministic polynomial-time hard (NP-hard) problem of heat exchanger network (HEN) synthesis is still challenging. In this study, we developed a novel optimization framework for efficiently solving large-scale HEN synthesis problems to obtain near global optimal solutions, simultaneously addressing the solution's infeasibility and time. The optimization framework consists of a multiple initial HEN design model (M-INI model), a new distance-based auto structure transformer (A-STR transformer), and a reduced non-linear programming model (R-NLP model). The M-INI model generates various HEN designs based on pinch analysis by varying the minimum approach temperature and the modes of stream splitting and mixing. The A-STR transformer is first proposed to automatically convert various HEN designs into associated superstructure-based topologies as multiple initial starting points for accelerating the solution of the R-NLP model. A strategy for approximating the temperature difference calculation is further applied to reduce the computational loads. Four case studies were conducted using the proposed method to minimize the total annual cost (TAC). The solutions of general cases 1 and 2 are almost equal to the best results in the literature, while the solution time is reduced by 98.7 % and 99.8 %, respectively, which demonstrates the performance of the proposed method. Especially, the method was applied to two practical industrial HEN cases: a large-scale low-grade heat recovery system and a crude distillation unit. The results of large-scale case 3 show that the optimal solution near the global optimal solution only requires 251.7 s. Case 4 includes pre-splitting in scenario A and free splitting in scenario B. Compared to scenario A, the TAC and solution time in scenario B were reduced by 33.9 % and 93.1 %, indicating that the pre-splitting strategy excludes the optimal from the search space. The proposed novel optimization framework demonstrates the efficiency and applicability of handling large-scale HEN synthesis problems. It can also guide engineers in the design of a large-scale HEN with lower costs and effort.

Investigation on a heat-driven thermoacoustic refrigerator with minimal complexity

Heat-driven thermoacoustic refrigerator (HDTR) emerges as a pivotal solution to global energy challenges and carbon emissions. This study introduces a simplified single-unit HDTR as a new supplement to the heat-driven thermoacoustic refrigeration process. Featuring only one simple, direct-coupled thermoacoustic energy conversion core unit, it is designed to reduce overall system complexity. Initially, the simulation model of the single-unit system is established in Sage and compared with a two-unit HDTR, indicating that reducing the number of thermoacoustic core units decreases system complexity without compromising system performance. The onset characteristics and steady-state operational characteristics of the proposed single-unit HDTR are then experimentally tested, revealing a cooling power of 895 W with a coefficient of performance (COP) of 0.43 when the ambient and cooling temperature is 25 °C and 0 °C, respectively. Notably, a minimal onset temperature difference of 61.6 °C is obtained for the single-unit HDTR. These results showcase the possible application potential for low-grade heat recovery. A comparative analysis against existing loop HDTR systems establishes its superior performance, offering a valuable reference for contemporary HDTR assessments. This study significantly advances HDTR development, emphasizing efficiency and sustainable cooling applications.

Screening Weldable Metal Electrodes for Ag2Se Thermoelectric Devices below 300 °C.

Thermoelectricity has been considered as the most important solution of generating electricity, particularly from low-grade heat below 300 °C. Despite efforts in recent years on exploring alternative materials to only commercialized Bi2Te3, the practical implementation of these new materials has been hindered by inadequate investigation into device design. Given that the utilization of weldable electrodes offers advantages in technical compatibility for a large-scale assembly of thermoelectric elements into modules, a thorough investigation into the potential of weldable metal electrodes at T < 300 °C is imperative. In this work, the diffusion of 11 kinds of thermoelectric materials in common weldable metals (Ni, Fe, Cu, and Ag) was screened. Ag is sorted out as a promising weldable electrode that can directly bond to thermoelectric Ag2Se in this temperature range, leading to a minimization of an interfacial contact resistivity down to 11 μΩ cm2 in a design of the Ag/Ag2Se/Ag structure. The conversion efficiency of ∼3% at ΔT of 95 K with an excellent stability indicates Ag2Se as a top alternative to n-type Bi2Te3 for low-grade heat recovery.

Design and Analysis of Pancake with Different Pitch Coil Heat Exchanger for Low-Grade Heat Recovery

Design and Analysis of Pancake with Different Pitch Coil Heat Exchanger for Low-Grade Heat Recovery

Efficient rhombohedral GeTe thermoelectrics for low-grade heat recovery

The existence of Ge vacancy induces an inherently hole concentration up to 1021 cm−3 in pristine thermoelectric GeTe, which results in a need of ∼10 % aliovalent dopants for optimization. However, the extra carrier scattering by the dopants would notably deteriorate the carrier mobility. In this work, CuSbTe2-alloying is revealed to increase the formation energy of Ge-vacancy, leading to a rapid reduction in hole concentration down to 1.3 × 1020 cm−3 but with a mobility above 100 cm2/V-s. Along with a further Pb-substitution at Ge sites for lattice thermal conductivity reduction and band alignment, a peak figure of merit zT of ∼2.4 at 625 K is eventually realized in the rhombohedral structure, leading to a specific power density of as high as 70 W/m and a conversion efficiency of ∼10 % under a temperature difference of 302 K. This illustrates r-GeTe as truly efficient thermoelectrics particularly for low-grade heat recovery applications.

All-Inorganic Halide Perovskites Boost High-Ranged Figure-of-Merit in Bi0.4Sb1.6Te3 for Thermoelectric Cooling and Low-Grade Heat Recovery.

The all-inorganic halide perovskite CsPbX3 (X = Cl, Br, or I) offers various advantages, such as tunable electronic structure and high carrier mobility. However, its potential application in thermoelectric materials remains underexplored. In this study, we propose a simple yet effective method to synthesize a CsPbX3/Bi0.4Sb1.6Te3 (BST) nanocomposite by sintering a uniformly mixed raw powder. The intrinsic excitation of the BST system is suppressed by exploiting the rich phase structure and tunable electrical transport properties of CsPbX3, and the thermoelectric properties were synergistically optimized. Notably, for CsPbI3, its phase-transition-induced dislocation arrays together with low group velocities drastically reduce thermal conductivity. As a result, the composite achieves an ultrahigh average figure-of-merit (ZT) of 1.4 from 298 to 523 K. The two-pair TE module demonstrates a superior conversion efficiency of 7.3%. This study expands the potential applications of inorganic halide perovskites, into thermoelectrics.

Enhancing operational optimization of district heating substations through refined estimations of network campus buildings heat demands to achieve a low return from the network

Network temperatures in district heating systems are important operational factors for obtaining efficient performance. A low network return temperature allows for the recovery of low-grade heat from assets such as condensing boilers, waste incineration, geothermal sources and industrial waste heat. Fluctuations in heating and cooling demands affect the return temperatures of the building substations and in the network. This variability impacts the economic viability and environmental sustainability of the entire system. This paper presents a nonlinear optimization strategy to maintain sufficient energy flows in the network's primary and secondary circuits to achieve low return temperatures from all substations in the network. The defined optimization strategy incorporates the thermodynamic model of the substation and building heating system as opposed to traditional weather-based supply temperature adjustments. The estimated heat demands and tariffs, ▪ penalties are inputs used by the optimizer to find the optimal solution. The total operational expenditure for electricity and gas consumption shows an 18% reduction with 8% reduction in emissions and 6% efficiency improvement when compared with the measured weather-based approach. The developed strategy will aid the network operators in the economic dispatch of heat generation while ensuring the user's thermal comfort.

Estimation of the effect of thin-plated surface on a three-staged looped thermoacoustic engine for low-grade heat recovery

This paper introduces two novel structures of looped thermoacoustic engines designed for outdoor low-frequency sound sources. The system consists of three thermoacoustic engines in a loop and a stub for sound radiating, which is characterized by reliability, high efficiency, and compactness. Two thin plates are used to prevent the Gedeon flow, facilitate sound propagation, and adjust the acoustic field. The system with a straight stub achieved a maximum Sound Pressure Level of 126.09 dB at 1 m away, surpassing highest reported records by 25.96 %. The system also achieves a high output efficiency of 3.86 %. The system with tapered stub and a 0.1 mm silicone plate, achieved an SPL of 120.76 dB at 1 m. To maintain the predetermined acoustic field, it is important to consider a thin plate with small Young's modulus and thickness. The effect on the acoustic field must be considered when the thickness exceeds 0.8 mm. The addition of the 0.28 mm thin plate in system with tapered stub resulted in a 7.8 W increase in acoustic power compared to that of system without the thin plate.

Full-scale numerical simulations of standing-wave thermoacoustic engines with circular-pore and pin-array stacks

Thermoacoustic engines (TAEs) can convert thermal energy into acoustic energy with no moving parts. Previous numerical studies normally focused on the TAEs with a parallel-plate stack due to their simple structures and used two-dimensional (2-D) computational fluid dynamics (CFD) models to save computational costs. In this study, we conduct full-scale three-dimensional (3-D) CFD simulations on the standing-wave TAEs with more complicated circular-pore and pin-array stacks. Firstly, the dynamic behavior of the standing-wave TAEs in the start-up process is investigated. It is found that the optimal ratios of hydraulic radius rh to thermal penetration depth δk for the TAEs with circular-pore and pin-array stacks are 2 and 3.2, respectively. Secondly, the acoustic, hydrodynamic, and thermodynamic characteristics of the standing-wave TAEs in the steady-state process are explored. We find that when operating at optimal rh/δk, the TAE with a pin-array stack generates much larger acoustic power than that with a circular-pore stack. Examination of the vortex shedding at the stack ends indicates that the pin arrays exhibit less flow resistance than circular pores. At optimal rh/δk, the time-averaged transversal heat flux at the pin array ends is calculated to be around 1.2 × 105 W/m2, which is larger than 7.5 × 104 W/m2 of circular pores, corresponding to a better thermodynamic performance. The 3-D numerical investigations in this work give deeper insights into the performances of TAEs with circular-pore and pin-array stacks which were investigated in experiments, providing useful guidance for the future design and development of more sophisticated thermoacoustic devices for low-grade heat recovery.

Energy efficiency analysis of novel combined open absorption multifunctional heat pump and FlashME desalination system with a compressed air dryer

Energy intensive thermal desalination and compressed air-drying processes coupled with low grade heat recovery units can significantly contribute to carbon and energy footprint reduction. In this paper, a novel combined system based on an open absorption multifunctional heat pump and FlashME desalination system with a compressed air dryer is proposed to recover the latent heat from flue gas and efficiently utilize it to drive the desalination process for seawater treatment and supply the compressed dry air. The energy performance of the combined system is analyzed under the effect of various key operational parameters by simulating the validated process model. The results of energy analysis indicate that the novel system can recover the latent waste heat from flue gas with an efficiency of 83.02 % and supply the compressed dry air at low humidity of 1.41 g/kg by operating at a thermal COP of 1.95. Furthermore, the system can efficiently utilize the recovered low-grade heat to produce freshwater at a recovery rate of 23.14 %. The findings of the critical performance analysis show that the drying, and latent heat recovery performance of the coupled system is dependent mainly on the inlet parameters of the spray solution and the flue gas humidity. However, the water recovery of FlashME is totally dependent on heat capacity and the regeneration pressure such that the performance ratio increases from 1.51 to 4.03 by operating with hot seawater of 60–80 °C, when the regeneration pressure is raised up to 53.48 kPa. Moreover, the coupled system configured in parallel double stage can lower 11.43–37.78 % regeneration load along with 54.24 % improvement in distillate productivity when the operating pressure is raised up to 800 kPa and the rise in airflow rate in dryer can decrease the 10.41–52.45 % regeneration load on external heat source.

Bi2Te3-Based Thermoelectric Modules for Efficient and Reliable Low-Grade Heat Recovery.

Bismuth-telluride-based alloy has long been considered as the most promising candidate for low-grade waste heat power generation. However, optimizing the thermoelectric performance of n-type Bi2Te3 is more challenging than that of p-type counterparts due to its greater sensitivity to texture, and thus limits the advancement of thermoelectric modules. Herein, the thermoelectric performance of n-type Bi2Te3 is enhanced by incorporating a small amount of CuGaTe2, resulting in a peak ZT of 1.25 and a distinguished average ZT of 1.02 (300-500 K). The decomposed Cu+ strengthens interlayer interaction, while Ga+ optimizes carrier concentration within an appropriate range. Simultaneously, the emerged numerous defects, such as small-angle grain boundaries, twin boundaries, and dislocations, significantly suppresses the lattice thermal conductivity. Based on the size optimization by finite element modelling, the constructed thermoelectric module yields a high conversion efficiency of 6.9% and output power density of 0.31W cm-2 under a temperature gradient of 200 K. Even more crucially, the efficiency and output power little loss after subjecting the module to 40 thermal cycles lasting for 6 days. This study demonstrates the efficient and reliable Bi2Te3-based thermoelectric modules for broad applications in low-grade heat harvest.

High-performance cryo-temperature ionic thermoelectric liquid cell developed through a eutectic solvent strategy

Ionic thermoelectric (i-TE) liquid cells offer an environmentally friendly, cost effective, and easy-operation route to low-grade heat recovery. However, the lowest temperature is limited by the freezing temperature of the aqueous electrolyte. Applying a eutectic solvent strategy, we fabricate a high-performance cryo-temperature i-TE liquid cell. Formamide is used as a chaotic organic solvent that destroys the hydrogen bond network between water molecules, forming a deep eutectic solvent that enables the cell to operate near cryo temperatures (down to –35 °C). After synergistic optimization of the electrode and cell structure, the as-fabricated liquid i-TE cell with cold (–35 °C) and hot (70 °C) ends achieve a high power density (17.5 W m−2) and a large two-hour energy density (27 kJ m−2). In a prototype 25-cell module, the open-circuit voltage and short-circuit current are 6.9 V and 68 mA, respectively, and the maximum power is 131 mW. The anti-freezing ability and high output performance of the as-fabricated i-TE liquid cell system are requisites for applications in frigid regions.

Enhanced Selective Ion Transport in Highly Charged Bacterial Cellulose/Boron Nitride Composite Membranes for Thermo-Osmotic Energy Harvesting.

Significant untapped energy exists within low-grade heat sources and salinity gradients. Traditional nanofluidic membranes exhibit inherent limitations, including low ion selectivity, high internal resistance, reliance on nonrenewable resources, and instability in aqueous solutions, invariably constraining their practical application. Here, an innovative composite membrane-based nanofluidic system is reported, involving the strategy of integrating tailor-modified bacterial nanofibers with boron nitride nanosheets, enabling high surface charge densities while maintaining a delicate balance between ion selectivity and permeability, ultimately facilitating effective thermo-osmotic energy harvesting. The device exhibits an impressive output power density of 10 W m-2 with artificial seawater and river water at a 50 K temperature gradient. Furthermore, it demonstrates robust power density stability under prolonged exposure to salinity gradients or even at elevated temperatures. This work opens new avenues for the development of nanofluidic systems utilizing composite materials and presents promising solutions for low-grade heat recovery and osmotic energy harvesting.

Design and experimental investigation of a micro-scale bladeless-type steam turbine

There are plenty of sources of waste heat available in industry that are not frequently utilised, especially when it comes to small-scale installations and low-grade heat recovery. The reason is that traditional methods are not cost-effective or unsuitable for given operating conditions. However, recent technological progress has made reusing waste heat more feasible, not only for generating thermal, but also electrical power. This paper presents a new design of a micro-scale bladeless steam turbine suitable for combined heat and power (CHP) applications where low-grade waste heat is used, or as a replacement for pressure-reducing valves used to meet the demands of steam processing technologies in many industrial facilities. A 20 kW prototype of the turbine has been designed, built, and experimentally investigated to analyse its performance parameters. The results show that the turbine maximum isentropic efficiency was close to 30%, demonstrating that the turbine can compete with other concepts of bladeless-type turbines or with bladed designs in a power range below 100 kW where efficient solutions can hardly be found.

Novel marine ejector-compression waste heat-driven refrigeration system: Technical possibilities and environmental advantages

A novel combined ejector-compression refrigeration system for provision rooms of merchant ships was conceptualized and analyzed. The principle possibility of recovery of onboard low-grade heat (85–95 °С) of jacket cooling water was confirmed. Two ejectors of different geometries to ensure the ejector stage operation when the seawater temperature varies in a wide range were designed and proposed to install in parallel. The performance of the combined system was compared to a vapor-compression one and the choice of the rational temperatures in the condenser-evaporator tC/Ev was performed. The combined system COPtotal is considerably higher than the vapor-compression system, and it weakly depends on heat source temperature. At condensing temperature tC = 34 °С the decreasing in tC/Ev from 20/15 to 10/5 °С results in increasing of COPtotal up to 13.5 % at generation temperature tG = 80 °С and up to 15.6 % at tG = 90 °С. Utilizing the combined system for the onboard cold production will contribute to fuel savings of 25 to 33 % per voyage (operation and transport) vs. vapor-compression system. The combined system inherent the lower specific CO2 emission per 1 kW h of cooling energy emrefr than the standard system for all considered operation modes. The value of emrefr for combined system at tC/Ev = 10/5 °C, tG = 80 °C and tC = 36 °C or tC = 42 °C is 23.1% or 18.3%, respectively, less than for the vapor-compression one. The approach to analysis proposed can be used for assessment of the feasibility of utilization of low-grade heat and the retrofit of ship refrigeration systems.

High-subsonic boundary-layer flows of an organic vapour

Boundary layers of Novec649, a low-global-warming potential fluid of interest for low-grade heat recovery, are investigated numerically by means of linear stability theory, direct numerical simulation (DNS) and large-eddy simulations (LES). This organic vapour is of interest in organic Rankine cycle (ORC) turbines and realistic thermodynamic conditions are selected. Under these conditions, the vapour behaves as a dense gas and, due to its high molecular complexity, real-gas effects occur. In addition, the fluid exhibits large and highly variable heat capacities and density- as well as temperature-dependent transport properties. More specifically we report the first direct and LES of transitional and turbulent boundary layers of Novec649 at high-subsonic conditions$M=0.9$. A controlled transition is performed by using oblique modes determined by linear stability theory extended to dense gases. An oblique-type transition is obtained as in low-speed air flows, where sinuous streaks develop by the lift-up mechanism and break down into turbulence. In the turbulent state, the profiles of dynamic flow properties (velocities, turbulent intensities, turbulent kinetic energy budgets) are little affected by the gas properties and remain very close to incompressible DNS, despite the high-subsonic flow speed. The fluctuations levels for thermodynamic properties have been quantified with respect to air flows. Notwithstanding a drastic reduction, genuine compressibility effects are present. For example, the fluctuating Mach number and the acoustic mode are characteristic of high-speed flows. The influence of forcing frequency and amplitude on the established turbulent state has been investigated using LES. An analysis of integral quantities shows a slow relaxation towards a canonical equilibrium turbulent state for all cases due to the high Reynolds numbers typical of dense gas flows. Overall the present DNS constitutes a valuable reference not only for forthcoming experiments but also for future studies of free-stream transition and loss mechanisms in ORC turbines.

Collaborative optimization of regeneration unit and power generation unit in reverse electrodialysis heat engine for low-grade heat recovery

Reverse electrodialysis heat engine (REDHE) emerges great potential to harvest the low-grade heat (LGH) produced during the industrial processes and renewable energy utilizations. In the closed-loop system, the power generation unit converts the salinity gradient power (SGP) to electric energy using the reverse electrodialysis (RED) cells, and the regeneration unit recovers the salinity gradient based on LGH. As two units are in series, the regeneration and power generation units should be collaboratively optimized to achieve a high performance of REDHE. Herein, a framework which can unitedly simulate the both units is built, which enables to divide the total efficiency of REDHE to the respective efficiencies of units. LiBr solution as the working fluid and the effects of initial salt concentration, concentration of the high concentration (HC) solution and temperature in RED cells are considered. Results show that the total efficiencies increase with the concentration of HC solution and the RED temperature due to the production of more chemical energy in the regeneration unit. However, a non-monotonic trend of the total efficiency with the initial concentration is discovered, which increases from 4.91% to 5.42% and then decreases to 4.69% when the initial concentration raises from 20 wt% to 25 wt% and then reaches 30 wt% at RED temperature of 25 ℃. Although enhancing the RED temperature to 50 ℃ leads the total efficiencies increase to 6.25%, 7.13% and 6.38%, respectively, the trend is unchanged. The respective efficiencies of units explain the phenomenon by that a higher salinity can decrease the efficiency of the power generation unit by reducing the ionic selectivity in the RED cells, but enhance the efficiency of the regeneration unit. Therefore, the highest total efficiency reached at initial concentration of 25 wt% is the trade-off between the efficiencies of two units. This study indicates that increasing the concentration of HC solution, the RED temperature, and carefully selecting a compromise initial concentration are helpful to achieve a high energy efficiency in a REDHE.

A comparative study on design and performance evaluation of Organic Rankine Cycle (ORC) under different two-phase heat transfer correlations

Organic Rankine cycle (ORC) is considered to be a good solution to the high-efficient recovery of low-grade heat for saving energy and reducing carbon emissions. As the core component, the heat exchanger plays a significant role in the thermo-economic performance evaluation of an ORC plant and its heat transfer correlations greatly influence the cycle performance. In this paper, 8 two-phase heat transfer correlations (4 flow boiling ones and 4 flow condensation ones) are utilized to design the plate-type heat exchangers, and a comparative study among different correlations is carried out. The result shows the designed evaporators are finitely affected by heat transfer correlations whereas the situation with the designed condensers is the opposite. The net output power is slightly influenced with a relative difference within 1.1% but the system's economic performance is significantly affected with the maximum relative difference of electricity production cost up to 11.2%. The environmental performance is hardly affected by correlations with the maximum relative difference of total greenhouse gas emission within 0.96%. This paper analyzed the performance variation of the ORC under different correlations and provided a guideline for designing heat exchangers and evaluating the off-design performance of ORC systems.

Techno-economic analysis of converting low-grade heat into electricity and hydrogen

Low-grade heat recovery has received increasing attention as an essential contributor to improving overall energy utilization efficiency and facilitating the carbon neutrality commitment. Here, we developed a techno-economic analysis model of converting low-grade heat into electricity and hydrogen via the osmotic heat engine (OHE) and power-to-gas facility to alleviate the dilemma of lacking practical application scenarios of waste heat. The contribution margin is optimized in real time by either sending the electricity generated by the OHE into the electrolyzer for hydrogen production or selling it at market price in Wuhan, China, thus to identify the economically viable OHE costs under different conditions. Results show that the allowed heat engine cost is significantly impacted by the capacity factor, lifetime and discount rate. The effect of the capacity size of power-to-gas facility on allowed heat engine cost strongly depends on the hydrogen price. The allowed OHE cost increases with the elevating waste heat temperature for each heat transfer scenario. The hybrid energy system can be economically competitive compared with current mature technologies when the waste heat temperature is higher than 68 ℃ and 105 ℃ for fluid and air as heat transfer fluid, respectively. The economically viable heat engine cost is expected to gradually decline from 50,043 ¥/kW to 18,741 ¥/kW within next 15 years. Incentive policy would boost the economic viability of converting low-grade heat into electricity and hydrogen.

Optimizing GeTe-based thermoelectric generator for low-grade heat recovery

GeTe-based thermoelectric (TE) materials have been of great interest in the field of low-grade heat recovery due to their increasing performance near room temperature. To promote the application of GeTe-based materials, we analyze the GeTe-based thermoelectric generator (TEG) from materials to structures through theoretical and experimental methods. Since a TEG generally contains both p-type and n-type materials, we calculate the n-type material parameters suitable for the p-type GeTe, and improve the compatibility between p-type and n-type materials by adjusting the ratio of cross-sectional areas. Meanwhile, the height of TE legs is designed to minimize the impact of interfacial resistivity, while the suitable temperature loading is determined to achieve higher output power and conversion efficiency. Based on theoretical guidance, the conversion efficiency is improved by more than 23% by adjusting the ratio of cross-sectional areas; a conversion efficiency of 6.24% under the temperature gradient of 300 K is realized, which has up to 80% improvement from the conventional TEGs with the advantages of low cost, high reliability and stable service performance. This study provides the theoretical basis and guidance for optimizing GeTe-based TEG in the application of low-grade heat recovery.