Temperature Waste Heat Research Articles

Techno-Economic Comparative Assessment of High Temperature Heat Pump Architectures for Industrial Pumped Thermal Energy Storage

Abstract The industrial sector is a key global source of wealth, but it is also recognized as a major challenge toward worldwide decarbonization. Today the industrial sector requires more than 22 % of the global energy demand as thermal energy and produces for this about 40 % of the total CO2 emissions. Solutions to efficiently decarbonize the industrial sector are deemed. This work presents a comparative techno-economic performance assessment of a high temperature heat pump integration within a molten salts based power to heat system for industrial heat flexible generation. The main system performance is reported in terms of required working conditions and temperature for the heat pump and thermal demand size as well as reduction of the attainable levelized cost of heat (LCoH) against non-flexible electric boiler based systems. The impact of different industrial load profiles, electricity prices, heat pump capital cost and heat pump real to Carnot efficiency ratio are also presented. The results highlight that the proposed system can be cost-competitive, particularly for thermal demand around 10 MW and waste heat temperatures above 80°C. Under these conditions LCoH reductions higher than 15 %, with respect to the considered non-flexible electric boiler alternative, are attainable. These LCoH reductions are primarily driven by savings in electrical consumption as high as 30 %. This study sets the ground for further power-to-heat techno-economic investigations addressing different industrial sectors and identifies main system and components design strategies, integrations, and targets.

Multi-objective optimization and influence degree analysis of the thermally integrated HP-ORC carnot battery based on the orthogonal design method and grey relational analysis

Thermally integrated heat pump (HP)-organic Rankine cycle (ORC) Carnot battery is a promising solution for efficient energy storage and waste heat utilization. Firstly, in order to research the influence degree of the operating parameters on the system performance, single-objective optimization is conducted by the orthogonal design method. Then, multi-objective optimization is conducted by combining the grey relational analysis (GRA) and orthogonal design method to assess the comprehensive performance of the system. The importance order and contribution rates of the operating parameters and the optimal operating combinations are determined. Finally, in order to explore the influence mechanism of the parameters on the system performance, the influence of the parameters on the subsystems and the subsystems on the whole system is quantitatively analyzed. The results show that thermal storage temperature difference, waste heat temperature difference and cold source temperature are the most important parameters affecting the comprehensive performance of the whole system. Under the optimal operating conditions, round-trip efficiency, exergy efficiency, energy storage capacity (ESC), energy storage density (ESD) and levelized cost of storage (LCOS) are 47.05 %, 22.66 %, 1943 kW, 2.90 kWh/m3 and 0.38$/kWh, respectively. Compared to the ORC subsystem, the HP subsystem is more important to round-trip efficiency and exergy efficiency.

Energy dataset of Frontier supercomputer for waste heat recovery

The Hewlett Packard Enterprise–Cray EX Frontier is the world’s first and fastest exascale supercomputer, hosted at the Oak Ridge Leadership Computing Facility in Tennessee, United States. Frontier is a significant electricity consumer, drawing 8–30 MW; this massive energy demand produces significant waste heat, requiring extensive cooling measures. Although harnessing this waste heat for campus heating is a sustainability goal at Oak Ridge National Laboratory (ORNL), the 30 °C–38 °C waste heat temperature poses compatibility issues with standard HVAC systems. Heat pump systems, prevalent in residential settings and some industries, can efficiently upgrade low-quality heat to usable energy for buildings. Thus, heat pump technology powered by renewable electricity offers an efficient, cost-effective solution for substantial waste heat recovery. However, a major challenge is the absence of benchmark data on high-performance computing (HPC) heat generation and waste heat profiles. This paper reports power demand and waste heat measurements from an ORNL HPC data centre, aiming to guide future research on optimizing waste heat recovery in large-scale data centres, especially those of HPC calibre.

Monte Carlo simulation of an ammonia adsorption refrigeration system based on calcium chloride impregnated nanoporous carbon.

We use Monte Carlo simulations to investigate the effect of incorporating calcium chloride salt into nanoporous carbon on the performance of an ammonia-carbon adsorption refrigeration system. Simulations of ideal carbon slit-pores with pore sizes of 1, 2, and 3nm, each containing calcium chloride with ion densities of 0.0, 0.25, and 0.5nm-3, were carried out at temperatures between 0 and 30 °C and ammonia pressures up to 15.0 bar. The results reveal that ideal 1nm pores are able to achieve a good refrigeration performance using waste heat below 100 °C to drive the process, but adding salt to these pores increases the waste heat temperature required beyond 100 °C. However, ideal 2nm pores require the addition of 0.25nm-3 salt to achieve a similar performance, while the 3nm pores were unable to achieve a satisfactory refrigeration performance. Considering that real nanoporous carbons usually feature a variety of specific adsorption sites and non-ideal geometries that should have a similar impact to adding salt, these results indicate that nanoporous carbons with pores in the range of 1-2nm are likely to hold the most promise for adsorption refrigeration applications and that the addition of salt may not always be helpful.

Performance of thermoelectric generator system to generate electrical output from a low-grade waste heat temperature under linear and swirling waste heat streams

A thermoelectric generator (TEG) module converts heat directly into electrical energy. Waste heat from a process is a viable heat source for TEG modules to support the energy sustainability agenda. A module was designed to recover low-temperature waste heat from a 1 kW fuel cell stack used in a mini hydrogen vehicle. The module was constructed using a single TEG cell that receives heat directly on its surface from the waste heat stream, coupled with a heat pipe connected to a finned heat sink to effectively cool the cold junction of the TEG cell. This research presents a comparison of the module characteristics when it is operated under direct impinging jet flow and swirl flow waste heat streams at 60°C, while the cold junction of the cell is cooled under stationary vehicle conditions (natural convection cooling) and cruising conditions (forced convection cooling) at an air speed of 5 m/s. Results indicate that the swirling effect increases the maximum power point (MPP) by 60%. The introduction of swirl to the heating stream is a viable approach to significantly enhance the recovery of low-grade waste heat using TEG. However, the MPP shows a greater increase of 70 to 80% due to the forced cooling effect, indicating that cold junction cooling has a more significant influence on the MPP compared to the swirl effect.

Evaluation of the high-robustness nuclear power cycle against lunar surface environmental threat

Heat sinks exposed to the lunar surface environment cause fluctuations in the energy cycle due to variations in lunar thermal conditions, leading to non-design operations of the energy system. Such suboptimal operations decrease energy efficiency and shorten the lifespan of system components. This paper introduces an innovative design for a highly robust lunar nuclear power cycle that mitigates environmental threats on the lunar surface. A reverse closed Brayton cycle increases the waste heat discharge temperature. Higher waste heat temperatures allow the heat sink panels to have greater heat radiation per unit area, countering the negative disturbances from lunar environmental changes on the energy system. Under the dual threats of lunar dust toxicity and intense solar radiation, the output reduction of this robust nuclear cycle is only 0.96% that of traditional nuclear power cycles with the same thermoelectric parameters. Moreover, even under severe environmental threats, the power quality of this robust nuclear cycle remains 10.8 times better than that of conventional designs with the same nighttime output design baseline. In conclusion, employing a reverse Brayton cycle to increase waste heat emission temperature effectively enhances the robustness of the nuclear power cycle. This paper proposes a new nuclear thermoelectric system framework to withstand threats from the lunar surface environment.

Thermal Performance Design and Analysis of Reversed Brayton Cycle Heat Pumps for High-Temperature Heat Supply

This study examined the performance of reversed Brayton cycle heat pumps to supply heat above 300 °C. The aim was to overcome the current temperature limitations faced by heat pump technology in industrial heat supply sectors by examining the viability of the reversed Brayton cycle. In particular, the effects of the operating conditions on the cycle performance, such as the waste and return heat temperatures, were analyzed through thermal performance analysis. The reversed Brayton cycle heat pumps showed improved performance over conventional vapor compression cycle heat pumps when a heat supply above 215 °C was required. Furthermore, integrating additional heat exchangers into the cycle configuration was proposed in this study as a method to enhance waste heat utilization and recover unused heat from industrial processes. By incorporating preheating and recuperated cycles, these modifications broaden the operational range under the same operating conditions. They also improve the coefficient of performance (COP) of the reference cycle by up to 23% and 27.4%, respectively. This study explored the potential of reversed Brayton cycle heat pumps to supply heat above 300 °C and provided fundamental guidelines for the efficient design and operation of reversed Brayton cycle heat pumps. The results are expected to enhance our understanding of the performance characteristics of reversed Brayton cycle heat pump technology and expand its use as an alternative to fossil-fuel-based heat supply systems.

Use of an Absorption Heat Pump to Lift the District Cooling Waste Heat Temperature for the District Heating Supply in Tallinn: a Technical and Economic Analysis

Absorption heat pumps can lift a lower temperature waste heat source to a higher temperature useful output. In that process, it uses less electricity as an input compared to heat pumps with electrical compressors. Therefore, in some cases, it can be used to lift a lower temperature waste heat source to a higher temperature useful output with less electricity consumption. Absorption heat pumps are not very widely spread in district heating, mostly because there aren’t many suitable waste heat sources or conditions needed to run them. Tallinn has a district heating system with an annual generation of more than 2 TWh and a goal to make it an entirely carbon neutral district heating system by 2030. Tallinn has also started to develop a district cooling network, and by the end of 2023, the installed capacity was about 6 MW. District cooling capacity is estimated to grow to around 100 MW in 2030. This paper investigates different types of absorption heat pumps and the possibilities of integrating an absorption heat pump to a district cooling plant with the purpose of using waste heat from the cooling plant for renewable heat generation, that can be used in district heating. Different technical aspects are examined to find a suitable production solution, are presented as results. From an economical point of view, the cost of heat to cover peaks with an absorption heat pump is calculated. The effect of reducing fossil fuel use in the Tallinn district heating network with an absorption heat pump is estimated.

Triple effect absorption refrigeration systems for the deep recovery of low grade waste heat

With regard to energy conservation, low grade waste heat recovery technology is attracting significant interest. The absorption refrigeration can significantly utilize waste heat. The current researches have devoted little attention to the recovery of waste heat at lower temperature. This paper presents three triple effect absorption refrigeration systems for the deep recovery of low grade waste heat, which can make use of more waste heat as low as 60 °C. The involvement of absorption heat transformer cycle enables the proposed systems to exploit waste heat at lower temperature. The models of three systems are established using EES software. Energy, exergy and economic analysis of three systems are conducted. The results indicate that the best of three systems can achieve a coefficiency of performance of 0.178 and the maximum exergy efficiency is 0.190. The triple effect absorption refrigeration systems not only generate more cold energy, but also demonstrate better economic performance than the previous cascade absorption refrigeration system. Except for the first system, the other two systems achieve reductions of 8.7% and 15.2% in the cost of unit cold energy respectively. This paper provides three novel approaches for producing high grade cool energy from lower temperature of waste heat.

Principal parameters of thermoelectric generator module design for effective industrial waste heat recovery

In the sustainable energy agenda, thermoelectric generators (TEG) can be a central technology for low-cost combined heat and power (CHP) systems. TEG module (TEM) is the combination of TEG cells, heat pipes, heat sinks and copper blocks that produce electrical power and thermal energy for low temperature heating simultaneously. Two TEG cells were used in each TEM for CHP in a bakery factory with a reference waste heat temperature of 250°C. Different designs of TEM affect the heat transfer mechanics through the components. However, actual testing of each design requires high cost and time consuming. Identifying the principal parameters affecting the desired output is indeed important before investing in actual design fabrication. One-dimensional model is developed in this manuscript to evaluate the fundamental interactions between each component. Parametric variation for nine main parameters characterized the steady-state response of each parameter under four novel heat sink configurations. The parameter sweeps approach benefits in designing a novel TEM for optimum system output. An improved TEM with 6 TEG cells was designed and it increased the heat recovery ratio from an initial 14% to 38%. The Reynolds number of streams are the major operating parameter as it influences the heat sink effectiveness. Large heat exchanger frontal area and copper block housing surface area are also significant parameters. Identification of these principle parameters would assist in effective designs of TEM systems for industrial CHP.

Multi-objective optimization and benefit evaluation of heat pump system for tobacco drying using waste heat from data center

Tobacco drying is a highly energy-consuming process that requires a large amount of thermal energy. In this study, the waste heat from a data center is utilized to reduce fossil energy consumption in the tobacco drying process. A heat pump system is designed to address the issue of the waste heat temperature from the data center not meeting the required temperature for tobacco drying. Multi-objective optimization is performed with the goal of maximizing the specific moisture extraction rate and minimizing the specific investment cost, and seven hydrofluoroolefins are selected as the circulating working fluids. Coal-fired tobacco drying and Air Source Heat Pump Tobacco Drying (ASHPTD) are selected as comparison benchmarks to evaluate the energy efficiency and environmental benefits of the Data Center Waste Heat Tobacco Drying (DCWHTD) method in this study. The results indicate that R1234ze(Z) is the best working fluid. The specific moisture extraction rate of DCWHTD is improved by 36.69% and 20.21% compared to the coal-fired tobacco drying and ASHPTD, respectively, demonstrating enhanced energy efficiency. Although the specific investment cost of DCWHTD is higher compared with the coal-fired tobacco drying, it is 21.00% lower than that of ASHPTD. DCWHTD produces fewer emissions, the life-cycle carbon emissions are 26.93% and 16.80% lower than that of the coal-fired tobacco drying and ASHPTD, respectively. Furthermore, waste heat recovery improves the energy reuse efficiency of the data center by 64.92%. The tobacco drying method proposed in this study has better comprehensive performance and greater application potential.

Waste heat recovery from the biomass engine for effective power generation using a new array-based system

Thermoelectric generator (TEG)-thermosyphon-based heat recovery system (HRS) for harvesting the heat from the high temperature sources is a well-known technology for power generation. However, various thermal resistances (a total of nine) are involved in the thermosyphon-based HRS between the heat sources and TEGs which generate irreversibility that ultimately reduces its performance. In this work, a new design of HRS i.e. TEG-array-based is proposed for effective power generation even at low temperatures of sustainable heat source by minimizing the thermal resistances. This TEG-array-based HRS is driven by a salt gradient thermal storage device (SGTSD) which is used for efficiently recovering and storing of sustainable waste heat generated from a biomass(renewable energy)-based engine-generator. The proposed system is experimentally studied to analyse the temperature variations in SGTSD, characteristics of sustainable waste heat temperature, and performance features of TEGs in terms of obtained electrical parameters, output power and conversion efficiency. The experimental results showed that the maximum open circuit voltage, output power and conversion efficiency of TEG are obtained as 81.62V, 7.438W and 4.63\\% respectively. With this proposed system, seven thermal resistances (out of total nine) are totally eliminated while the others two are lowered that leads to effectively transfer the energy from sustainable heat source to TEGs via minor equivalent thermal resistance of 0.01198oC/W. The proposed system is found to be capable of charging a 12 V, 80 Ah heavy-duty battery for real life applications.

Energy, exergy, economic, and environmental analysis of a high-temperature heat pump steam system

Industrial steam is widely recognized as a valuable form of heat currency, possessing considerable social and economic significance. As the industry shifts to low carbon emissions, there is an urgent need to reduce CO2 emissions from industrial steam generation. The analysis of a high-temperature heat pump steam system (HTHPSS), which recovers industrial waste heat to produce high-temperature steam at 170 °C, includes evaluations of its energy, exergy, economic, and environmental (4E) to determine whether it can replace a coal-fired boiler. The economic analysis considered the recovery value of waste heat and the effect of CO2 trading prices. Optimization calculations were performed to investigate changes in the waste heat temperature and condenser outlet temperature. The study also offers recommendations for operational conditions and optimization strategies for the HTHPSS. The results indicate a positive correlation between the system coefficient of performance (COP) and the waste heat utilization rate with waste heat temperature and condenser outlet temperature. The maximum COP value is 2.73. The total exergy efficiency initially increases and then decreases as waste heat temperature increases. It also decreases as the condenser outlet temperature increases, reaching a peak value of 43.26 %. The waste heat temperature needs to be at least 59 °C to generate a net profit, with a corresponding payback period (PBP) of 4.40 years. The minimum PBP is 0.03 years, independent of waste heat temperature. The annual emission reduction increases as waste heat temperature increases and decreases as condenser outlet temperature increases. These results indicate that a HTHPSS could replace a coal-fired boiler and offer guidance for design optimization.

Experiment and calculation of charge and release characteristics of phase change electronic heat storage system

A phase change heat storage device for an active thermoelectric heat pump was tested for its heat storage and release performance at different operating voltages and heat source temperatures. A study on heat release/discharge characteristics of a phase active heat exchanger is proposed. The experimental results show that there are significant differences in heating/discharging time and operating performance of the device under different operating conditions and heating conditions. When the operating voltage is high and the temperature of waste heat is high, the heating time of the device is short. Continuing to increase the voltage efficiency during this period will increase the temperature difference between the cold and hot ends of the semiconductor chip, decrease the heat coefficient of the device. Compared to passive phase change heating equipment, the best way of this equipment is to adjust the voltage. Adjusting the operating voltage in a suitable manner can maximize its heat/discharge efficiency, while overcoming the shortage of heat-supply equipment in low voltage secondary heat storage systems, and cannot improve the inequality between supply and demand in terms of time, position, and energy.

High-performance flexible thermoelectric devices with a copper foam heatsink for personal thermal management

A Bi2Te3-based thermoelectric device with high thermoelectric performance and flexibility for human body waste heat recovery and temperature management.

Use of Absorption Heat Pumps to Raise District Cooling Waste Heat Temperature for District Heating Supply in Tallinn: Technical and Economic Analysis

Abstract Decarbonisation of District Heating (DH) networks is essential to achieving the European Union’s climate goals. In this context, there is growing interest among DH stakeholders in the recovery and reuse of underutilised heat sources. Waste heat recovery from district cooling (DC) networks offers a compelling option that can be used as input for various heat pump integrated DH solutions. In this regard, absorption heat pumps (AHP) showcase a promising solution to elevate a lower-temperature waste heat source with reduced electricity consumption. However, AHPs are not widely applied in DH context, primarily due to the lack of suitable waste heat sources or the necessary conditions for their effective operation. This article aims to explore various configurations of AHP and their potential integration with DC plant waste heat for DH application. The potential for adopting AHPs to boost efficiency and lower carbon emissions is evaluated through a techno-economic examination of three distinct technological configurations. For Tallinn case study, it was observed that AHPs can be more efficient, reduce energy consumption, and achieve a lower LCOH while being combined with HP condenser cooling. This study is expected to provide a theoretical support for the positive impact of using AHPs to reduce the usage of fossil fuels in the Tallinn DH network.

Innovative approaches for deep decarbonization of data centers and building space heating networks: Modeling and comparison of novel waste heat recovery systems for liquid cooling systems

The data usage surge drives greater data center demand, amplifying global CO2 emissions. Mitigating climate change necessitates reducing data center CO2 emissions. Reusing waste heat from data centers offers a potential energy efficiency boost and environmental impact reduction. This study utilizes liquid cooling technology to raise waste heat temperature for building space heating and introduces the concept of ‘data furnaces,’ where data centers directly supply waste heat to heat buildings on-site, reducing district heating consumption and lowering CO2 emissions. Efficiently designing a heat recovery heat exchanger system that accounts for both heat rejection and cooling sides of a liquid cooling system is crucial for achieving complete heat recovery without using heat pump, a commonly overlooked aspect in existing literature. To address this issue, we propose two heat exchanger schemes: connecting the building space heating network to the secondary side (Scheme 1) and the primary side (Scheme 2) of the cooling distribution unit. Implementing these innovations leads to the elimination of dependence on a heat pump, substantially cutting energy and CO2 emissions. Using TRNSYS software, we develop, model, and compare waste heat recovery schemes to curb district heating consumption and CO2 emissions. To demonstrate broad implications of the proposed approaches for energy efficiency and sustainability in the data centers and building space heating networks, a showcase study examines constant 25 kW waste heat from a direct-to-chip liquid-cooled rack in an office building with 285.7 MWh annual space heating demand. A novel waste heat recovery rate relationship graph is created to assist system design, uncovering an unexpected result in Scheme 2: waste heat recovery decreases as outdoor temperature falls. In contrast, Scheme 1 maintains a stable waste heat recovery rate around 25 kW, regardless of outdoor temperature fluctuations. As a result, Scheme 1 reuses 155.2 MWh of waste heat annually compared to 138 MWh for Scheme 2. Schemes 1 and 2 yield annual electricity savings of 2290.5 kWh and 905.2 kWh, respectively, for the cooling system. Both schemes achieve profitability within a year through a 25-year life cycle analysis (LCC) and substantially reduce CO2 emissions, with Scheme 1 saving 291,996 kgCO2 and Scheme 2 saving 258,192 kgCO2. The study addresses critical gaps in existing literature by emphasizes LCC. The proposed heat exchanger designs represent pioneering solutions for optimizing waste heat recovery, particularly in challenging climates. New findings offer substantial benefits to both liquid-cooled and air-cooled facilities, making significant contributions to achieve carbon neutrality in data center operations.

A three-heat source segmented heating control strategy based on waste heat recovery technology for electric vehicles

The control strategy of thermal management systems is crucial for electric vehicles to ensure thermal comfort of the cabin and thermal safety of the battery and motor. However, this will also impact the energy consumption of the vehicle. In this study, a three-heat source segmented heating control strategy was proposed to reduce the heating energy consumption of electric vehicles, with the three sources denoted motor waste heat, air, and positive temperature coefficient (PTC) heaters. Specifically, a simulation model of an integrated thermal management system for heat pump air conditioning, motor thermal management, and battery thermal management systems was first established and validated using published experimental results. Subsequently, the performance of three cabin heating modes was investigated based on the standard driving cycle. The optimal opening and closing strategies for each mode were discussed to ensure the temperature requirements of the cabin, and the optimal method for using motor waste heat and the PTC heater to heat the battery at low temperatures was explored. The segmented heating control strategy was developed by determining the heating priority for the battery and cabin, as well as the heating capacity of heating modes using air source. Compared to the traditional heating strategy of the cabin and battery, the proposed control strategy could reduce energy consumption by 18.49 % while running at an ambient temperature of − 10 °C for 2.5 h.

Performance of Single Cell and Double Stacked Thermoelectric Generator Modules for Low Temperature Waste Heat Recovery

Thermoelectric generator (TEG) is an energy conversion technology that is capable of converting temperature difference into electrical output. This manuscript focused on different design setups of TEG module in recovering waste heat captured from hydrogen fuel cell vehicle (FCV) into useful electrical energy. Effects of single cell (SC) and double stacked (DS) TEG configurations were analysed before an additional heat sink (HS) was installed in the heating section for heat transfer enhancement. The performance of all design setups was tested under waste heat temperature (Twh) of 53°C and 58°C. Under Twh of 58°C, the maximum power point (MPP) was enhanced from 0.23mW/cm2 (SC TEG design setup) to 2.8mW/cm2 (DS TEG configuration with HS addition design setup), by approximately 92%. Rapid increase in MPP was obtained as HS was applied in the TEG module due to higher rate of waste heat capturing. The installation of HS is proved to be a successful add-on to the TEG module for WHR from low temperature waste heat.

Design and Thermodynamic Investigation of a Waste Heat‐Assisted Compressed Air Energy Storage System Integrating Thermal Energy Storage and Organic Rankine Cycle

Compressed air energy storage (CAES) technology has attracted growing attention because of the demand for load shifting and electricity cost reduction in energy‐intensive industries. To increase the round‐trip efficiency and energy storage density and simplify the structure of advanced adiabatic CAES (AA‐CAES) systems, a waste heat‐assisted CAES (WH‐CAES) design integrating a tube‐in‐tube thermal energy storage unit and an organic Rankine cycle (ORC) is described herein. Thermodynamic models of the proposed WH‐CAES system are established, and the effects of waste heat temperature, ratio of compression ratios, ratio of expansion ratios, and air storage cavern pressure on the performance of different systems, including AA‐CAES and WH‐CAES with and without ORC, are investigated. The results show that when the waste heat temperature is 500 °C, the input work of the compressors reaches its minimum value at a ratio of compression ratios of 1.14, and the optimal ratio of expansion ratios is 0.39. Under these optimal operating conditions, compared with the AA‐CAES system, the round‐trip storage efficiency, energy storage density, and system energy efficiency of the WH‐CAES system can be increased significantly. The findings validate the potential of the proposed WH‐CAES system.