Dr Hussam (Sam) Jouhara BSc (first), PhD, CEng, IntPE, FIMechE, MIEI, MInstR, FHEA

Transcription

1 Mechanical Engineering College of Engineering, Design and Physical Sciences Institute of Energy Futures HEAT PIPE BASED SYSTEMS FOR INDUSTRIAL WASTE HEAT RECOVERY AND RENEWABLE ENERGY MANAGEMENT By Dr Hussam (Sam) Jouhara BSc (first), PhD, CEng, IntPE, FIMechE, MIEI, MInstR, FHEA Reader (Associate Professor)

2 OVERVIEW The potential of the heat pipe technology in challenging waste heat recovery applications Heat pipes, an overview Typical configurations of heat pipe units for waste heat recovery applications Case studies Conclusions

3 Challenging Waste heat recovery scenarios

4 Challenging waste heat recovery scenarios Many industrial processes generate highly difficult exhaust conditions that can be characterised as follows: 1. High temperatures / mass flows 2. High particulate content that is abrasive and / or can cause fouling 3. Highly corrosive, acidic content SO2, SO3, NO2, etc. Heat pipes can manage these difficult conditions!

5 What Does The Solution Consist Off? Why Does The HP Solution Work Where Conventional Units Don t? 1. HP metal temperature can be kept above the acid dew point. 2. Eliminates any localised acid condensation (cold spots). 3. Easy to clean. 4. The risk profile on pipe failure is minimised due to the multiple redundancy. Systems delivered to date have delivered sub 24 month payback

6 Heat Pipes What are they?

7 Low temperature heat pipe Working fluid High temperature heat pipe

8 Heat Pipe

9 Multiple Redundancy Each pipe operates independently so unit is not vulnerable to a single pipe failure This prevents cross contamination each heat pipe acts as an additional buffer between the two fluids Intermediate Pipe Working Temperature Allows higher exhaust temperature limits on some applications Better fouling managment Use of smooth pipes allows exchangers to be used in high particulate or oily applications Ease of Cleaning & Maintenance Can be maintained in situ (no uninstall) Manual/automated cleaning systems Highly Scalable, Customisable & Configurable Modular design allows on site assembly Can be designed for future expansion, to meet specific application or operational needs Isothermal Operation no hot or cold spots Eliminates cold corners and condensation Allows greater energy recovery Better longevity for thermal oil Reactivity Fast reaction time, offers different control options and suitable for sensitive apparatus: does not require preheating Robust Materials and Long Life Design allows pipes to freely expand and contract, thus no thermal stress on structure Thick pipe walls resist erosion/corrosion Passive devices No need for pumping energy to drive the heat transfer process through the heat pipe

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12 Typical geometries of heat pipe based waste heat recovery systems

13 A schematic of a typical heat pipe unit

14 Heat pipe units: typical configurations Standard cross flow HP heat exchangers Air preheaters Gas to water Gas to thermal oil Steam generators Modular cross flow HP heat exchangers Gas to water Gas to thermal oil Throughflow HP heat exchangers

15 Cross flow HP units: Gas to air

16 Cross flow HP units: Gas to air Hot exhaust Preheated combustion air Cooled exhaust to the new stack Cold combustion air Heat pipe heat exchanger

17 Cross flow HP units: Gas to air 10m HOT STOVES WASTE GAS HEAT RECOVERY

18 Cross flow HP units: Gas to air

19 STEAM GENERATION FROM WASTE HEAT 14 April 2017 Duty: Circa 6MW Steam generation rate: 8t/h ROI: < 7 months Heat pipe based systems Dr Hussam Jouhara,,

20 Thermal Storage And Heat Recovery System From Process Waste STEAM 14 April 2017 Discharging Charging Heat pipe based systems Dr Hussam Jouhara,, 2016

21 14 April 2017 Presentation Title 21

22 14 April 2017 Bundle of heat pipes Cooled exhaust Connecting adaptors Water from installation Preheated water Inspection plate Hot exhaust Presentation Title 22

23 14 April 2017 Municipal Incinerator, Italy, Gas to Water for district heating system Presentation Title 23

24 14 April 2017 Presentation Title 24

25 14 April 2017 Exhaust side, bottom view Working inside a unit Oil chamber and baffles Water chamber and baffles Gas to water through-flow Presentation Title 25

26 14 April 2017 Maintenance Panels Manual cleaning with compressed air or high pressure water Pipes rows are easily accessible by lance Aerodynamic trap Regular dust removal Automated actuator Moving plate system Active vibration device Sonic Horn - Inside unit Cleaning / Anti-clogging Solutions Presentation Title 26

27 Cross flow HP units: Gas to water

28 Cross flow HP units: Gas to thermal oil

29 Cross flow HP units: Steam generator

30 Cross flow HP units: A combination of various units

31 Modular cross flow HP units

32 Modular cross flow HP units

33 Throughflow HP units Through-Flow = for exhaust temperatures above 500C

34 Steam Condenser, Food, Dirty Steam, Ireland

35 SAMPLES OF RECENT PROJECTS G2W, Shale Gas Well Head Fracking, Thermal Oxidiser, Canada 2013

36 Heat Pipe Based Waste Heat Recovery Systems: Case Studies

37 Steam Generator, China National Offshore Oil Corp, China Sea, April April 2017 Gas to Steam Exhaust Temp In/Out 400 C/250 C Water/Steam Temp In/Out 50 C/180 C Exhaust Flow/Steam Rate 130,000/ 8,000 Kg/h Energy Recovered 6.4 MW Recovered Energy 2,100K p/a Project Cost 1,200K Payback Period 7 Months /KW recovered 328 GA 6400 smooth pipe 2 stage steam generator On-site assembly High reliability required for offshore location Low footprint required by space limitations Instant start up from gas turbine Multi Redundancy Robust Material Efficient Cleaning & Maintenance Low Pressure Drop Low Fouling Working Temperatures Scalable & Customisable Reactivity Isothermal Operation 37

38 Gas to Air Unit, Automotive, Aluminium Furnace, USA 2008 Gas to Air Exhaust Temp In/Out 400 C/266 C Air Temp In/Out 30 C/293 C Exhaust/Air Mass Flow 12,000/ 6,374 Kg/h Energy Recovered 528 KW Recovered Energy $155K p/a Project Cost $150K Payback Period 16 Months $/KW recovered $123 ( 76) Multi Redundancy Robust Material Efficient Cleaning & Maintenance Low Pressure Drop Low Fouling Working Temperatures Scalable & Customisable Reactivity Isothermal Operation GA 360 smooth pipe heat exchanger 500 kw combustion air pre-heater High particulate matter exhaust from furnace Low fouling, easy cleaning and maintenance, high reliability Unit positioned outside main factory premises Customer advised it was not possible by consultants (acid etc) 38

39 Exhaust to Coke Gas Unit, Steel mill Blast Furnace, Czech Republic 2011 Gas to Air Exhaust Temp In/Out 286 C/156 C Coke Gas Temp In/Out 62.2 C/197 C Exhaust/Air Mass Flow 97,551/97,551 Kg/h Energy Recovered 12,626 KW Recovered Energy 800K p/a Project Cost 400,000 * Payback Period Circa 6 Months * /KW recovered * * Estimated figures based on extrapolated installed costs Heat pipe GPH Multi Redundancy Robust Material Efficient Cleaning & Maintenance Low Pressure Drop 12.6 MW duty Each unit consists of 1575 X 7.6 Mtr helically finned, distilled water stainless steel heat pipes Low Fouling Working Temperatures Scalable & Customisable Reactivity Isothermal Operation Unit performance increased significantly after upgrade Repeat order secured Sep 2013 delivery Full turnkey replacement delivered through Czech local distributor 39

40 G2W, Shale Gas Well Head Fracking, Thermal Oxidiser, Canada 2012 Gas to Water Exhaust Temp In/Out 816 C/ 150 C Water Temp In/Out 5 C/ 16 C Exhaust/Water Mass Flow 11,016/180,000 Kg/h Weight of unit 3,600 Kg Exhaust pressure drop 800 Pa Energy Recovered 2,260 KW Recovered Energy Value 360K p/a Heat Exchanger Cost 65K Payback Period <3 Months Price per KW recovered 27 Multi Redundancy Robust Material Efficient Cleaning & Maintenance Low Pressure Drop Low Fouling Working Scalable & Reactivity Isothermal Temperatures Customisable Operation GW 2000 hybrid pipe heat exchanger 2.2MW fracking water heater: highly robust mobile unit for travelling around Canada High particulate matter exhaust from furnace; removable panels incorporated for cleaning Low fouling, easy cleaning and maintenance, high reliability 40

41 Multi-stage, in series, steam/water, natural gas, Spirax Sarco Italy 2012 Multi-stage Steam Generator and Water Pre-Heater Exhaust Temp In/Out Water Temp In/Out Exhaust/Water Mass Flow Weight of unit Exhaust pressure drop Energy Recovered Recovered Energy Value 420 C/ 160 C 160 C/ 198 C (12 bar) 11,484/ 900 Kg/h 1852 Kg 700 Pa 520 KW 19K p/a Heat Exchanger Cost 19K Payback Period 12 Months Price per KW recovered 36 Multi Redundancy Robust Material Efficient Cleaning & Maintenance Low Pressure Drop Low Fouling Working Temperatures Scalable & Customisable Reactivity Isothermal Operation Anaerobic digester genset in food industry 1 stage of 198C/12 Bar steam generation, left hand side 2 stages of water heating delivered by 2 standard modules, visible on right of unit Pipes screwed in from underneath on standard modules; modules can be removed individually Hinged access doors for easy cleaning, sealing nuts will be replaced by latches on future units 41

42 Steam Condenser, Food, Dirty Steam, Ireland, 2010 Steam Condenser / Hot Water Steam Temp In/Out 105 C/ 95 C Water Temp In/Out 10 C/ 88 C Exhaust/Water Mass Flow 844 / 8,000 Kg/h Weight of unit 300 Kg Exhaust pressure drop N/A Energy Recovered 446 KW Recovered Energy Value 2 x 20K p/a Heat Exchanger Cost 2 x 10K Payback Period 6 Months Price per KW recovered 22 Multi Redundancy Robust Material Efficient Cleaning & Maintenance Low Pressure Drop Low Fouling Working Temperatures Scalable & Customisable Reactivity Isothermal Operation SC model 400 smooth/finned hybrid pipe through-flow heat exchanger 440 kw process water heater Contaminated steam; regulatory requirement to condense, fuel savings, stainless steel Eliminated existing air-cooled equipment 42

43 G2W, In Line Through-Flow Recuperator, Biomass Incinerator, Bologna, Italy Gas to Water Exhaust Temp In/Out 610 C / 150 C Water Temp In/Out 73 C / 90C Exhaust/Water Mass Flow 17,500 Kg/h Weight of unit 5,000 Kg Exhaust pressure drop 400 Pa Energy Recovered 2,100 KW Recovered Energy Value 315K p/a Heat Exchanger Cost 172,500 Payback Period <18 Months Price pe r KW recovered 140/kW Multi Redundancy Robust Material Efficient Cleaning & Maintenance Low Pressure Drop Low Fouling Working Temperatures Scalable & Customisable Reactivity Isothermal Operation GW throughflow heat exchanger 2.1MW waste water treatment plant biomass incinerator plant: highly robust low fouling unit High organic particulate matter in exhaust; removable panels incorporated for cleaning Low fouling, easy cleaning and maintenance, high reliability 43

44 3 Kiln Heat Recovery, RAK Ceramics, UAE, April 2016 Gas to Air Exhaust Temp In/Out Air Temp In/Out Exhaust/Air Mass Flow Energy Recovered Recovered Energy 235 C/162 C 34 C/160 C 41,771/ 27,400 Kg/h 970 KW 209K p/a Project Cost 190K Payback Period 11 Months /KW recovered 195 GA 970 smooth pipe heat exchanger 970 kw drier air pre-heater sourcing exhaust from 3 tunnel kilns Pre-heated air delivered to multiple usage points High particulate matter exhaust from kilns Integrated moving plate cleaning system

45 TDO Heat Pipe Recovery, COSMO Films Limited, February 2016 Exhaust to Air Exhaust Temp In/Out Air Temp In/Out Exhaust/Air Mass Flow Energy Recovered 140 C/80 C 35 C/105 C 13,200 Kg/h 219 kwth Recovered Energy Project Cost Payback Period /KW recovered Econotherm GA 970 smooth pipe heat exchanger Reduced energy consumption by returning existing heat energy - Up to 220 kw per hour Improvement of film quality by - Preheated fresh air - Reduced temperature differences - Reduced pressure differences Higher air conformity in the TDO oven Less maintenance in the TDO - By controlled absorption of condensate - By simple collection and removal Less emission to the environment Less condensate at slots, holes and cold bridges by - Reduced flow of cold air - Controlled overpressure in the oven

46 Air Pre-Heater, Dow Chemicals, Freeport, Texas Gas to Air Exhaust Temp In/Out Air/ Temp In/Out 360 C/142 C 26 C/254 C Exhaust/Air Flow Rate 46,856/ 49,124 Kg/h Energy Recovered 3,100 KW Recovered Energy 563K p/a Project Cost 750K Payback Period 19 Months /KW recovered 241 Econotherm GA 3100 finned pipe counter flow air pre-heater Ethylene cracking furnace combustion air pre-heater Distilled water working fluid pipes ASME design code compliant, fully NDT tested Carbon steel finned pipe design

47 Installed Units

48 14 April 2017 Advances in heat pipe research 48

49 Funded Waste heat recovery activities in the Heat Pipe Research Group

50 14 April 2017 Presentation Title 50

51 100 Heat Pipes Have been installed in a lab scaled prototype unit - POC 14 April Heat Pipes installed Presentation Title 51

52 14 April 2017 Safer drying process due to separating the exhaust from the drying fluid Any bio-mass fuel can be used more sustainable biomass can be utilised Tremendous reduction in by-product waste used as biomass SENAI is looking into the use of Pyrolysis to enhance the quality of the new biomass. Presentation Title 52

53 Results from the 100-pipes prototype unit 14 April 2017 POC proven! Presentation Title 53

54 Funded by DECC The Flat Heat Pipe

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57 13/01/16 Presentation Title 57

58 Patents 1. Jouhara, H., Lester, S., (2014), "Heat Transfer Apparatus", UK patent application No Status: Filed. Filing date: 19/06/2014. Applicant: Flint Engineering & Econotherm (UK) ltd. 2. Jouhara, H., Lester, S., (2014), "Radiator", UK patent application No Status: Filed. Filing date: 19/06/2014. Applicant: Flint Engineering.

59 Thank you