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IDRIST Estimations of the market potential for high temperature PCMs for industrial heat recovery Thorsten Spillmann 1 29/06/2015 IDRIST - Thorsten Spillmann Contents IDRIST project introduction Classification of industrial processes

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IDRIST Estimations of the market potential for high temperature PCMs for industrial heat recovery

Thorsten Spillmann

29/06/2015 IDRIST - Thorsten Spillmann 1

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Contents

  • IDRIST project introduction
  • Classification of industrial processes
  • Production process
  • Energy consumption
  • Temperature levels
  • Examples from the food processing industry
  • Preliminary conclusions

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IDRIST Project Phases

1. Market Potential

1. Identify industry needs and market potential (100-300ºC)

2. Integrated PCM thermal storage systems

1. Identify and characterise candidate PCMs 2. Design laboratory tests and simulation 3. Experimental evaluation & model validation 4. System modelling for industrial applications

3. Thermo-chemical heat storage and transformation

1. Short list salt-refrigerant working pairs using ideal thermodynamics

4. Whole systems modelling

1. Business models, techno-economic assessments 2. Whole system performance modelling

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Model of industrial production process

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Step 1

Raw material 1 … Raw material n Heat utility Cold utility Electricity

Step 2 Step n Storage

Product 1 … Product n

Heat Integration Storage Step 2 Step n Step 2 Step n

continuous batch

Unit Processes

Source: Thollander and Palm (2013) Improving Energy Efficiency in Industrial Systems

  • Decomposing
  • Mixing
  • Cutting
  • Joining
  • Coating
  • Forming
  • Heating
  • Melting
  • Drying/Concentrating
  • Cooling/ Freezing
  • Packing

11 Production Processes

  • Lighting
  • Compressed Air
  • Ventilation
  • Pumping
  • Space heating/ cooling
  • Hot water heating
  • Internal transport

7 Support Processes

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Batch vs. Continuous Production

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Advantages Disadvantages Good for small amounts of speciality chemicals Frequent start up and shutdown of equipment Make a range of products using same equipment Cleaning time between batches Good for developing new products May be batch to batch variability Easier to scale up from lab scale Not good for bulk chemical production Generally cheaper set up costs Advantages Disadvantages Good for large volumes (bulk chemicals) Requires periodic shutdown of whole plant for inspection and maintenance Fewer start up and shutdowns May rely on critical pieces of equipment which have the potential to stop production on whole plant Potentially greater yields Higher initial costs Potentially easier to maintain quality

Batch Process Continuous Process

Source: C. McEvoy (2010) The Industrial Manufacture of Chemical Compounds. www.ulster.ac.uk

Example: Chemical Industry

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Applications for thermal storage

  • Continuous Process
  • Transportation of heat
  • Long-term storage
  • Batch Process
  • Heat recovery between operation to reduce heat loss of cooling

down equipment

  • Chemical Processing: Heat input to reach reaction

temperatures, heat removal during exothermic reaction

  • Food production: Cooking of product, subsequently cooling to

down for storage.

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Approach for identification of relevant industries

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1. Fuel demand of industrial sectors 2. Temperature Ranges of relevant processes and common production practices 3. Identification of relevant subsectors 4. Temperature ranges and heat demand of target industries

 preselection: Food& Tobacco, Pharmaceuticals, small scale Chemicals, Textiles

  • Energy Audit documents (Einstein II)
  • Best Available Techniques Reference

Documents

  • IEA Tracking Emissions Report (2007)
  • National Allocation Plan (2004)
  • Estimations for industrial waste heat

recovery

  • Solar thermal industrial heat applications

Sources of Information

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Fuel Consumption in the UK

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Source: IEA statistics (http://www.iea.org/sankey/)

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Subsector Emissions in 2003 (NAP II) for Food & Beverage and Chemical Industries

29/06/2015 IDRIST - Thorsten Spillmann 9 data from 9 postcodes not displayed data from 11 postcodes not displayed

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European Industrial Energy Demand

29/06/2015 IDRIST - Thorsten Spillmann 10 Source:

  • G. P. Hammond. 2007. Industrial energy analysis,

thermodynamics and sustainability. Applied Energy 84: 675-700

*Calculations based on

data from 1987 *

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Temperature levels of individual processes

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  • Ammonia: Hydrogen production 1,000ºC
  • Soda ash: Calcination 950-1,100ºC
  • Petrochemicals: Steam cracking 760-850ºC
  • Coke making 850-1100ºC
  • Furnaces 1,200-1,600ºC
  • Casting 700-900ºC
  • Cement (70-80%): Rotating kiln 1,500ºC
  • Lime: Calcination 1,000ºC
  • Glass: Furnace 1,575ºC, Annealing 580ºC
  • Chemicals (30%): 33.63EJ*
  • Iron & steel (19%): 21.44EJ
  • non-metallic minerals (9%): 10.61 EJ
  • Pulp & paper (6%): 6.45 EJ
  • Textile & leather (2%): 2.17 EJ
  • Food & Beverages (5%): 5.98 EJ
  • Pulp Pre-steaming & Impregnation 110ºC
  • Pulp Digester Cooking 170-176ºC
  • Pulp Bleaching 130-150ºC
  • Paper Drying 60-80ºC
  • Cooking, Bleaching 60-90ºC
  • Sterilising 100-140ºC
  • Baking 100-300ºC
  • Pasteurising 60-95ºC
  • Drying 120-180ºC
  • Bleaching, Dyeing 60-90ºC
  • Fixing 160-180ºC
  • Pressing 80-100ºC
  • Drying 100-130ºC

* worldwide primary energy demand most relevant sectors

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Nature of industrial sectors

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Sectors Heterogeneous Homogeneous

  • 3
  • 2
  • 1

1 2 3 Iron & Steel + Aluminium + Cement + Lime + Glass + Ceramics + Paper & Pulp + Unclassified + Food & Drink + Chemicals +

Source: McKenna and Norman (2010) Spatial modelling of industrial heat loads and recovery potentials in the UK

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Example Food & Tobacco Sector (1/3): Dairy

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  • L. Wang. 2009. Energy Efficiency and

Management in Food Processing

  • Facilities. CRC Press
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Example Food & Tobacco Sector (2/3): Baking

29/06/2015 IDRIST - Thorsten Spillmann 14 Source:

  • L. Wang. 2009. Energy Efficiency and

Management in Food Processing

  • Facilities. CRC Press
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Example Food & Tobacco Sector (3/3): Brewery

29/06/2015 IDRIST - Thorsten Spillmann 15 10ºC 20ºC 30ºC 40ºC 50ºC 60ºC 70ºC 80ºC 90ºC 100ºC 1st drying of green malt 2nd drying of green malt Cleaning of bottles and cases Cleaning of production halls and equipment Production of brewing water Pasteurisation of beer Mashing Wort heating Wort boiling Source: 2014Mauthner - Manufacture of malt and beer with low temperature solar process heat

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Preliminary conclusions

  • Applicability of thermal storage is broadest in batch

production

  • Food & Beverage and Chemical Industry appear to be most

promising target industries

  • 90% of processes in the food industry are at temperature

levels below 200ºC the majority of those below 120ºC

  • Due to the diversity of the respective sectors, a detailed

analysis of site specific processes are necessary to obtain relevant information for the system design (e.g. storage capacity, discharge rates, etc.)

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Thank you for your attention!

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