Waste Heat Utilization Research Articles

Correction: Wet spinning of the graphene oxide composite liquid crystals toward graded utilization of waste heat

Correction: Wet spinning of the graphene oxide composite liquid crystals toward graded utilization of waste heat

Waste Heat Utilization in Marine Energy Systems for Enhanced Efficiency

The maritime industry, central to global trade, faces critical challenges related to energy efficiency and environmental sustainability due to significant energy loss from waste heat in marine engines. This review investigates the potential of waste heat recovery (WHR) technologies to enhance operational efficiency and reduce emissions in marine systems. By analyzing major WHR methods, such as heat exchangers, Organic Rankine Cycle (ORC) systems, thermoelectric generators, and combined heat and power (CHP) systems, this work highlights the specific advantages, limitations, and practical considerations of each approach. Unique to this review is an examination of WHR performance in confined marine spaces and compatibility with existing ship components, providing essential insights for practical implementation. Findings emphasize WHR as a viable strategy to reduce fuel consumption and meet environmental regulations, contributing to a more sustainable maritime industry.

A systematic methodology for selecting optimal technology for waste heat utilization in food processing industry

Utilizing waste heat that is rejected from thermal processes can greatly enhance the industry's energy balance. Identifying potential waste heat sources in the food and beverage processing industry and making estimations for their possible utilization can be an extremely challenging undertaking. To determine waste heat potentials in the food processing industry and to select an optimal technology for its utilization a novel systematic methodology based on the comprehensive energy audit and mathematical optimization has been developed. The developed mixed integer nonlinear programming model incorporates all novel and the most commonly employed technologies to utilize waste heat.The developed systematic methodology is tested on a case study, of a milk and dairy production facility. Obtained results have shown that up to 53 % of the available waste heat can be used in the scenario of limited investment costs. Otherwise, in the scenario when investment costs are not set as a limitation, 75 % of waste heat can be used, according to plant demands. Harmonising production processes is necessary to use all the waste heat. The developed systematic methodology can be applied to any food processing industry and other facilities producing waste heat because it presents a universal approach.

Performance of a novel waste heat-powered ionic liquid-based CO2 capture and liquefaction system for large-scale shipping

In this work, we proposed a novel CO2 capture and liquefaction system for large-scale shipping using ionic liquid as capture solvent. By utilizing the waste heat of the exhaust gas and jacket cooling water from the ship’s engine as well as the residual pressure energy of the N2-O2 mixture from the CO2 absorption and desorption process, the system’s net energy consumption has been significantly reduced. We established the thermodynamic model of the system and investigated the effect of 10 primary system operational parameters on system performance with 3 different ionic liquids as CO2 capture solvent. The results demonstrated that the system with [DEME][TF2N] as the CO2 capture solvent had the best system performance. In addition, we performed a multi-parameter optimization of the system using simulated annealing algorithm with net energy consumption as the optimization objective and the minimal net energy consumption is 0.467 GJ/tCO2. Compared to the CO2 capture system that do not utilize waste heat and residual pressure energy, the net energy consumption was reduced by 57.29 % under optimal operational conditions which proves that the novel system significantly reduces the energy consumption of the CO2 capture and liquefaction process.

Research on control strategy of electric vehicle thermal management system motor

Abstract The low efficiency and difficulty in low-temperature heating are the challenges currently faced by the thermal management system of new energy vehicles. A multi-heat source vehicle thermal management system for waste heat cascade recovery and utilization was proposed, and the performance of the vehicle thermal management system was studied through a combination of component testing and one-dimensional simulation. Based on a one-dimensional simulation model, the characteristics of the motor waste heat source are analyzed. The increase in the inlet water temperature of the motor coolant will lead to enhanced heat dissipation of the motor to the air, resulting in a waste of motor waste heat. Based on the results of the analysis, an energy cascade management strategy is constructed. The optimal heating mode is selected by collecting temperature signals such as motors, and the cut-off valve is controlled through logic gates to achieve flexible switching of different modes. The system effectively reduces the energy consumption of thermal management systems, which is of great significance for developing thermal management systems for new energy vehicles.

CFD numerical simulation, verification with experimental results and internal flow analysis of bristle turbines

In industrial facilities, a considerable amount of waste heat is often generated. However, due to the high costs associated with traditional methods of recovery, which do not align with the economic interests of enterprises, this waste heat is frequently wasted. With technological advancements, the bristle turbine has been proposed as a solution capable of effectively managing waste gases and providing added value to enterprises. Its advantages lie in its simple structure, easy installation, low rotational speed, and high reliability, offering a new option for waste heat recovery and utilization. Despite its potential, no previous research has conducted a detailed simulation of the bristle turbine, particularly focusing on internal flow dynamics, energy loss mechanisms, drag forces, and entropy generation. This study is the first to explore these critical aspects, making a novel contribution to the field. The paper presents the computational fluid dynamics (CFD) simulation of a 20 kW bristle turbine. The numerical simulation results are in good agreement with experimental results. Subsequently, the isentropic efficiency of the turbine at different speeds is simulated, and the performance of the turbine under off-design conditions is analyzed. By investigating the energy loss mechanisms within the turbine, optimization designs are proposed.

Development of membrane distillation powered by engine exhaust for water desalination

To address water shortage in arid areas and make use of waste heat, an experimental investigation is presented for a novel system of air gap membrane distillation unit driven by an engine exhaust heat source for the development of an on-board car water desalination. The design of the gas-to-water heat exchanger is presented and optimized. The system’s performance, governed by the achieved feed water temperature and measured by the output vapor mass flux, is evaluated with time under varying operational parameters, including engine load, engine speed, and feed water flow rate, with the analysis of production cost for economic viability. Experimental results revealed that higher engine loads and speeds lead to rapid temperature increase of the feed water, enhancing the efficiency of the membrane distillation process and increasing the permeate flux. Notably, a maximum permeate flux of 45 kg/m2h was achieved after 40 min of operation. A minimum production cost of 3.2 $/m3 is estimated at an engine load of 35 N.m. With production costs ranging from 3.2 to 5.8 $/m3, the proposed system emerges as a highly competitive option when compared with other membrane distillation systems driven by waste heat in literature. This study underscores the potential of utilizing waste heat from car engines for cost-effective and sustainable water desalination, paving the way for further development and implementation of the system as a mobile desalination unit for different applications.

Energy, exergy, exergo-economic and exergo-environmental analysis of waste heat-based convective dryer

Food drying is a widely used method of food preservation worldwide, and the utilization of waste heat from exhaust flue gas presents a significant opportunity to reduce the energy consumption of industrial drying processes. This study thoroughly examines the energy and exergy efficiency, sustainability indicators, and various exergo-environmental and exergo-economic parameters to assess the performance of a waste heat-based convective dryer (WHCD). The study found that drying at 70 °C performed the best (among 50 °C, 60 °C and 70 °C) for the overall drying process, with a maximum overall exergetic efficiency of 4.89 %. The results of exergo-economic analysis revealed that the drying chamber exhibited the highest exergy destruction cost at US$0.01193 per hour, and it was determined that improving the drying chamber was of paramount importance. An exergo-environmental assessment indicates that the proposed dryer effectively mitigates 14.15 tons of CO2 over a 20-year lifespan. Sensitivity analysis of the proposed system reveals that the energy efficiency is more sensitive to the food drying temperature than the exergy efficiency. A 33 % increase in drying temperature increases the exergy efficiency by 19.37 % while reducing the energy efficiency by 37.54 %. Hence, adopting the proposed system in industrial settings could significantly enhance energy-efficient and sustainable food drying processes.

Research on performance and potential of distributed heating system for peak shaving with multi-energy resource

Climate change and its negative effects are driving the global shift from fossil fuels to renewable energy sources. To tackle the dependency on traditional energy sources in harsh winter regions and improve heating quality during periods of thermal demand fluctuations, this paper proposes a new distributed heating peak shaving system (DHPS). The system combines municipal heat and clean energy within the secondary network while reducing the return water temperature in the primary network. It comprises solar collectors, electric thermal storage tanks (ETST), and absorption heat pump (AHP) units, integrated into conventional heat exchange stations. The system operates in two modes to manage peak and off-peak loads respectively, with TRNSYS simulation used to evaluate performance across a range of peak-shaving gradients. A multidimensional comprehensive assessment is conducted between the DHPS under optimal peak shaving coefficient (θ) conditions and conventional peak clipping boiler (PCB). Results indicate that DHPS achieves a high primary energy ratio (PER) of 1.251 at θ = 0.5, reducing combustion emissions by nearly 40%. The static payback period (PBP) of the system is 3.5 years. When the electricity price drops to 0.275 CNY, its operational costs are comparable to PCB. DHPS caters to the energy characteristics of cold regions where electricity supply exceeds demand. It enables flexible peak shaving while ensuring the complete utilization of clean energy and effectively utilizing waste heat from power plants.

Optimizing Motorcycle Manufacturing Sustainability through the Integration of Waste Heat Recovery and Metal Scrap Recycling: A Process Engineering Approach

The automotive industry manufacturing has experienced rapid growth 2–3 times by 2050, with motorcycles constituting around 30% of vehicles worldwide, but this increase in production has significantly heightened the demand for raw materials and energy. A major challenge arises in managing material waste and waste heat generated during the manufacturing process. This research aims to develop a framework that optimizes the synergy between material waste recycling and waste heat recovery to enhance the sustainability of the motorcycle industry, reduce waste, and lower energy consumption. The design leverages waste heat from the melting process to preheat raw materials, raising temperatures from around 50 °C to 350 °C before melting, thereby reducing additional energy needs, lowering emissions, and decreasing operational costs. Utilizing waste heat for preheating not only mitigates environmental impact and thermal load but also significantly improves energy efficiency, ultimately resulting in cost savings and optimized resource use. Utilizing waste heat directly for preheating raw materials has effectively lowered energy consumption by as much as 30%. This approach not only improves operational efficiency but also decreases production costs and minimizes environmental impact, offering a more sustainable solution for the manufacturing sector.

Effect of air layer on PCMs melting process inside a spherical container: A numerical investigation

Efficient latent heat storage technology is getting significant interest from the researchers, scientist, and engineers who are involved in solar heating and cooling, waste heat utilization, and building energy management applications. The latter materials are employed most frequently in this connection owing to their pronounced energy storage capacity and moderate cost. The present work involves a numerical analysis for the assessment of heat transfer through paraffin wax RT42 when it is fully converted from solid to liquid phase in a spherical container with and without air layer. The interaction of the py-porosity combination was evaluated numerically with the use of ANSYS/FLUENT 16 program. The results show that the presence of a 1 mm thick air layer increased the total melting time by 33.33%, while a 2 mm thick air layer resulted in a 66.67% increase compared to the control without an air layer. In this research, it is clear that air layers play a major role in the delay of the melting of paraffin wax.

Optimizing building energy efficiency with a combined cooling, heating, and power (CCHP) system driven by boiler waste heat recovery

In light of increasing challenges related to fossil fuel consumption, global warming, and rising energy costs, optimizing energy systems has become essential. This study introduces a multi-purpose system designed to capture and utilize waste heat from boiler flue gases at the Tous power plant for simultaneous power generation, cooling, and heating. The system integrates an Organic Rankine Cycle (ORC) for power generation and an Absorption Refrigeration Cycle (ARC) for cooling, with the added function of recovering waste heat to preheat natural gas for the boiler and power plant. The system's performance was rigorously analyzed through energy, exergy, and exergoeconomic assessments. To determine the optimal operating conditions, a multi-objective optimization was conducted using the TOPSIS technique, focusing on critical parameters such as flue gas exit temperature, natural gas inlet temperature, and turbine inlet pressures. The results identified optimal conditions with a flue gas exit temperature of 532.5 K, a natural gas inlet temperature of 285 K, and turbine inlet pressures of 2.54 MPa and 14.62 MPa for the first and second turbines, respectively. Under these conditions, the system achieved an exergy efficiency of 41.1 %, cooling capacity of 133.1 kW, power generation of 210.4 kW, heat transfer to natural gas of 979.6 kW, and operational costs of 8.53 $/h. This study highlights the potential of the proposed system to significantly enhance energy efficiency and reduce operational costs in practical applications, offering a sustainable solution for energy management.

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.

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.

An efficient carbon-neutral power and methanol polygeneration system based on biomass decarbonization and CO2 hydrogenation: Thermodynamic and economic analysis

This study presents a novel approach to enhance methanol synthesis (MS) efficiency through integration with an MEA-based decarbonized biomass direct-fired power plant (BFPP-CCS). The integration optimizes the utilization of chemical energy from feedstocks by combining exothermic MS reactions with diverse thermal energies, which effectively captures chemical energy through synergistic utilization from MS and various thermal inputs. Gradual methanol conversion maximizes both its chemical and fuel properties. Through such integration, the enhancement of waste heat and purge gas utilization in MS and BFPP carbon capture processes results in a 3.42 MW improvement in power generation and a 26.0 % reduction in associated energy penalties from CCS. Analysis of a 150 kton/yr MS facility and a 35 MW BFPP-CCS demonstrates 2.87 % increase in overall efficiency and reduction in CCS heat consumption by 1.03 GJ/tCO2. Moreover, this integrated approach yields a 33.1 M$ NPV increase and 3.4 years DPP decrease, achieving carbon-neutral power and liquid fuels production. Sensitivity analysis indicates the polygeneration system performs optimally around 250 °C and 60 bar, with a preference for 0.90 MS recycle ratio. Additionally, factors such as carbon recovery rate, electrolysis efficiency, and fixed carbon content in biomass are quantitatively revealed as crucial for maximizing carbon mitigation potential.

Waste heat utilization: Energy and economic benefits from multi-ejector chiller sub-cooling R744 supermarket refrigeration systems

This study investigated the energy and economic benefits of a novel sub-cooling technique using a heat-driven multi-ejector chiller (HDEC) in R744 supermarket refrigeration systems. Two configurations were evaluated: a conventional booster system with HDEC (CBEC) and a parallel compression system with HDEC (PCEC). Among various natural refrigerants, R717 was identified as most suitable for the HDEC. Various multi-ejector combinations were examined to assess the potential for waste heat utilization and energy savings in the R744 refrigeration system. The CBEC system provided effective operation only at ambient temperatures above 31 °C, whereas the PCEC system was effective above 24 °C. Performance of the proposed configurations were compared with a conventional R744 booster system (CB) and a parallel compression system (PC) both devoid of HDEC. The PCEC system showed improvements in the coefficient-of-performance ranging from 4.2 % to 23.9 % at ambient temperatures between 28 °C and 40 °C compared to the baselines. In various warm-climatic zones, including India, the Middle East, Thailand, and the USA, energy savings of approximately 2.1 %–9.5 % were observed compared to the PC system. Economic analysis indicated a reasonable payback period of 2.1–2.7 years for the additional investment required for deploying the PCEC system in Phoenix.

Selection of refrigerant based on multi-objective decision analysis for different waste heat recovery schemes

Waste heat generation, upgrading, and refrigeration are the fundamental ways to recover and utilize waste heat. The rationalizing the use of refrigerants also contribute in creating energy savings and minimizing carbon emissions. This study evaluated the thermodynamics, economics, and environmental of different types of refrigerants in three kinds of waste heat recovery schemes: generate electricity, heat pump, and refrigeration. Based on this, the entropy weight and Technique for Order Preference by Similarity to an Ideal Solution (TOPSIS) were combined to assess the overall performance of the refrigerants. A thorough analysis revealed that R1234ze(E) can replace R245fa and R123 in the organic rankine cycle (ORC). The best refrigerant for vapor compression refrigeration (VCR) and high temperature heat pump (HTHP) systems is R1243zf. In addition, the multi-objective decision analysis shows that the performance difference among the nine selected refrigerants is the total cost, followed by the environmental impact. The approach is successful in recognizing the variations between different refrigerants in the same waste heat recovery scheme and gives a thorough evaluation. It sets instructions for the future use of eco-friendly refrigerants and their application waste heat recovery schemes.

4E analysis of novel waste heat-driven combined cooling and power (CCP) systems based on modified Kalina-ejector refrigeration cycles

Global warming and environmental pollution are becoming increasingly severe problems due to the excessive use of fossil fuels. Recovering and utilizing waste heat from different energy systems can considered a sustainable solution to this destructive trend. This study proposes two modified Kalina cycle structures that use ejector refrigeration for combined cooling and power (CCP) generation in low-temperature waste heat. While to recover energy from a lean ammonia solution uses a two-phase expander. Thermodynamic analysis shows that the modified Kalina cycles E and F operate with a thermal efficiency of 0.3066 and 0.2557, respectively, representing a significant improvement of more than 123% and 86%, respectively, compared to the base cycle. Also, the exergy efficiency of the improved configurations E and F has been calculated as 0.083 and 0.089, respectively, showing an improvement of 53.8% and 64.8%, respectively, compared to the base cycle. The exergoeconomic analysis also revealed that the total capital cost rate for improved cycles E and F is estimated at 2.62 and 2.76 $/h, respectively. In addition, from an environmental perspective, the improved Kalina cycle F has proven to have a more eco-friendly performance with a pollution index of 0.2281 mPts/s. Moreover, a parametric study is conducted to investigate and analyze the effect of changes in significant performance parameters such as ammonia concentration, evaporator temperature, turbine inlet temperature and pressure, and turbine back-pressure for both presented modified cycles.

Unlocking the potentials using humidifier-dehumidifier for proton exchange membrane fuel cell waste heat recovery

This study addresses the dual challenges of waste heat dissipation and operational longevity degradation in proton exchange membrane fuel cells (PEMFCs) by proposing a novel hybrid system that integrates PEMFC with a humidifier-dehumidifier (HDH) unit. The primary objective is to enhance the energy efficiency and sustainability of PEMFC systems by leveraging waste heat for freshwater generation. A comprehensive mathematical model based on thermodynamic and electrochemical principles is developed to capture the system’s inherent irreversible losses. The performance metrics, including power density, energy efficiency, and exergy efficiency, are evaluated through systematic computational simulations. The proposed PEMFC/HDH hybrid system achieves a maximum power density of 4.8292 W cm-2 and an energy efficiency of 17.30%, showing a 1.48% improvement over standalone PEMFC systems. Parametric studies reveal that optimizing operating pressure significantly enhances system performance, while factors such as increased PEM thickness and thermodynamic loss composite parameter hinder it. Local sensitivity analysis identifies PEM thickness as the most critical parameter affecting performance. This research pioneers the integration of PEMFC and HDH for cogeneration, offering a viable path for performance enhancement and efficient waste heat utilization. The findings contribute to the strategic design and operational regulation of PEMFC-based hybrid systems for sustainable energy solutions.

Efficient waste heat utilization in high-temperature proton exchange membrane fuel cell bus through integration of lithium bromide absorption refrigeration

Compression-type air-conditioning heat pump systems used in high-temperature proton exchange membrane fuel cell (HT-PEMFC) buses significantly increase the vehicle's hydrogen consumption. This study introduces a lithium bromide (LiBr) absorption refrigeration air-conditioning system into a fuel cell bus, aiming to convert the high-quality waste heat produced by the HT-PEMFC into cooling and heating capabilities for balancing the temperature within the vehicle cabin and recover waste heat. Modeling and co-simulation of the HT-PEMFC, LiBr absorption refrigeration system, vehicle thermal model, and compression-type air-conditioning heat pump system were conducted using MATLAB/Simulink. The simulation results indicate that, compared with the traditional compression-type air-conditioning heat pump system, the LiBr absorption refrigeration system can save 6.13–18.17 % of hydrogen and improve the electrical energy and exergy efficiencies by 3.58–10.74 % and 3.74–11.22 %, respectively, under different driving scenarios. Using the LiBr absorption refrigeration system significantly enhances the vehicle's overall fuel utilization efficiency and driving range.