Heat pipe based heat exchangers in challenging industrial waste heat recovery applications

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1 Heat pipe based heat exchangers in challenging industrial waste heat recovery applications Authors: S. Almahmoud, G. Bianchi, S. A. Tassou, R. Llera, F. Lago, J. J. Arribas Ramirez and H. Jouhara Researcher: Sulaiman Almahmoud Supervised by: Dr Hussam Jouhara

2 Overview The Thermal Design of a Flat Heat Pipe (FHP) for waste heat recovery by radiation high temperature sources A theoretical model to predict the thermal performance was built The Mechanical Design of the FHP The Results obtained from testing the unit in the Laboratory 2

3 Aims Design a Flat Heat Pipe heat exchanger (FHP) to capture the heat by radiation and convection from High and medium temperature sources 3

4 Introduction Total operating cost 40% 60% Energy consumption in steel industry presents 5% world energy consumption 40% of total operating cost is for Energy cost Challenges: Limited Space, Inaccessibility, Temperature Restrictions Payback periods, Project and investment costs Other costs Energy costs 4 4

5 Research Gap Waste Heat recovery in steel industry Facility: Wire Rod Mill Product: Wire Rod Average Temperature: 500 ºC to 600 ºC 5

6 Flat heat pipe Thermal Design Pipe wall The outside wall of the condenser Condenser T c R co T ci T co R cond_c T v R ci RR hpp = RR cccccccc_ee + RR eeee + RR cccc + RR cccccccc_cc The outside wall of the evaporator T h T eo T ei Evaporator QQ hpp = TT eeee TT cccc RR hpp R eo R cond_e R ei 6

7 Flat Heat Pipe Design Forced convection heat transfer T cold, out T cold, in Water out Two phase Water in heat transfer Radiation heat transfer 7

8 FHP Design Rupture Disk Water out Water in Balance Weight 8

9 FHP Design 9

10 FHP Concept Inclination angle:12.5 Distance from the Barrier 10

11 Lab Testing 11 11

12 Lab Testing Thermocouple Positioning: 3 Thermocouples on the bottom header 5 Thermocouples on the pipes 3 Thermocouples on top header Thermocouples to measure the water inlet and water outlet 12 12

13 Lab Testing Experimental Conditions Test # Heater temperature Heater power FHP inclination angle from the vertical Water flow rate Water inlet temperature C 580 C 25 kw 29 kw L/min = 0.42 kg/s 10.6 C 13 13

14 Results Electrical heaters Power: Test 1: 25 kw, Test 2: 29 kw Heater temperature: Test 1 :500 C, Test 2: 580 C Water Flow rate 25 L/min = 0.42 kg/s Test 1 Test Temperature C Temperature C Time (s) Time (s) HP 1 HP 2 HP 3 HP 4 HP 5 Back Panel 14

15 Results Electrical heaters Power: Test 1: 25 kw, Test 2: 29 kw Heater temperature: Test 1 :500 C, Test 2: 580 C Water Flow rate 25 L/min = 0.42 kg/s Max outlet temperature: 17.3 C & 17.1 C Temperature C Test 1 Temperature C Test Time (s) Time (s) EV 1 EV 2 EV 3 AD 1 AD 2 AD 3 Inlet Water Outlet Water 15

16 Results Electrical heaters Power: Test 1: 25 kw, Test 2: 29 kw Heater temperature: Test 1 :500 C, Test 2: 580 C Water Flow rate 25 L/min = 0.42 kg/s Max heat transfer Experimental: 11.4 & 11.5 kw 14 Test 1 14 Test 2 Heat transfer reate (kw) Heat transfer reate (kw) Time (s) Time (s) Experimental Theoretical 16

17 Acknowledgements This project has received funding from the European Union Horizon 2020 research and innovation programme under grant agreement No

18 Thank you 18

19 Additional Slides 19

20 Testing In Factory Steel temperature 450 C, Air flow velocity m/s, Air temperature 136 C International conference on advances in energy systems and environmental engineering (ASEE17) 20

21 Testing In Factory International conference on advances in energy systems and environmental engineering (ASEE17) 21

22 Results Hot wire temperature 500 C to 600 C, Water flow rate 25 L/min High and low density of steel wires, Distance from the barrier 65 cm and 5 cm Heat transfer rate (kw) (a) Test # Heat transfer rate (kw) (b) Test # Time (s) Time (s) International conference on advances in energy systems and environmental engineering (ASEE17) 22

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