Intelligent storage concepts in the industry. Jürgen Fluch. TEM Food and Drink Industry, 26th of March 2012

Transcription

1 Intelligent storage concepts in the industry Jürgen Fluch AEE Institut for Sustainable Technologies (AEE INTEC) A-8200 Gleisdorf, Feldgasse 19 AUSTRIA

2 Overview Storage technologies state of the art Design of storages Available algorithms Algorithms used in tools Storages in the brewery industry case studies Outlook Technologies and concepts for optimised design and implementation in processes Roadmap Masterplan Storage Optimisation Concepts Challenges

3 Storage technologies state of the art (1) Sensible fluid storages Sensible heat stored in fluid mediums as water, pressurised water, thermal oil, liquid brine Long-term experiences in several industry sectors Sensible steam accumulator Sensible heat stored in pressurised water including phase changes while charging and discharging Experiences available but limited use due to requirements of pressure vessels

4 Storage technologies state of the art (2) Sensible heat stored in solid storages Solid medium with integrated heat transfer Medium: concretes Practical testing but limited use Latent heat storages - PCM Isothermal storage in medium changing phases while charging and discharging Medium: technical salts Tests in lab-scale, almost no experience in industry

5 Storage technologies state of the art (3) Long term use of sensible heat storages (esp. water storages) in different industry sectors Challenges Bad storage management (control, integration of processes, charging and discharging) No optimised integration and combination of processes in storages (different temperatur levels, operating hours) No optimised design of storages (discharging, insulation, heat losses, connections) Use of existing storages (no optimised capacity, relation of dimensions, no optimised adaptions)

6 Design of storages included in Pinch analysis (1) Realisation of the existing improvement potential on thermal energy in industry (Schnitzer et al, 2007 / Brunner et al, 2008) Demand site reduction via 3 step approach Technological optimisation (measure to enhance energy efficiency) System optimisation (Pinch Analysis of a total production site) Integration of renewable energy (based on exergetic considerations)

7 Design of storages included in Pinch analysis (2) Curves Generation of the Hot Composite Curve Generation of the Cold Composite Curve Generation of the Grand Composite Curve Pinch point Generation of a heat exchanger network Consideration of all hot and cold streams Design of the heat exchanger network

8 Design of storages included in Pinch analysis (3) Batch processes algorithms without storage consideration TAM time average method proposed for batch processes applying the same procedure as for continuous processes (Linhoff et al, 1988) Time slice model for HEN and batch heat integration (Linhoff, Kemp, Pourali) in each time interval targets for hot and cold utility consumption are identified over the problem table algorithm all utility targets added to find the minimum utility during the batch period only direct heat exchangers in time intervals can be identified need for scheduling Scheduling (Adonyi et al, 2003) Search for a schedule that requires minimal external energy

9 Design of storages included in Pinch analysis (4) Batch processes algorithms with storage consideration Time dependent heat cascade analysis (Kemp, McDonald, Zhao) Minimum units targeting based on time dependant heat cascade analysis (Foo et al, 2008) Permutation method (Stoltze et al) Rematching (Zhao et al, 1998) Storage pinch approach (Krummenacher and Favrat, 2001)

10 Storages in heat exchanger networks (1) EINSTEIN HEN algorithm for processes that are variable in time selection of matches is done based on an algorithm, partly drawn from the pinch algorithm suggested by Kemp et al Heat exchangers are really simulated taking into account their true operational schedules leading to slightly too low or high mass% Set a initial Cp Select hot stream with highest heat capacity flowrate Cp Run through all cold streams (loop) - Calculate heat capacity flowrate Cp of each cold stream - Check whether difference in Cp is smaller than allowable difference - Calculate the temperature range in which hot and cold stream overlap - The maximum transferable power is calculated between the hot and cold streams - The loop re-starts for the next cold stream Check for further availability of the hot stream Calculation stops when all cold streams are matched

11 Storages in heat exchanger networks (2) PE² - Combinatorial approach to design HEN for batch processes Main steps use three criteria Power of heat exchanger Transferable energy if necessary over storage Exergy Definition of the combination of different streams within the system in order to design the heat exchanger network The weight of these criteria runs from The best ranked heat exchanger network (based on its energy saving potential) is finally chosen

12 Storages in heat exchanger networks (3) Storage consideration Adapted time slice model calculate energy transferred over a heat exchanger for non- continuously processes Storage calculations limited to hot buffers integral part of the heat exchanger network design to calculate the transferable energy Example: 2 hypothetical streams A (waste heat) and B (energy demand) Calculation of available hot energy and necessary heating demand heat surplus, energy demand, accumulated energy Maximum amount of storageable heat converted to a tank

13 Storages in heat exchanger networks (4) Heat exchanger design algorithms including storages Continuous processes Batch processes Integration of solar thermal as a batch Algorithm tested Food industry: breweries, dairy Metal surface treatment industry Tools PE² EINSTEIN SOCO

14 Storage concepts in the brewery industry Data collection and energy and mass balances Pinch analysis Würzekühlung Brauwasser, 1990m³ 85 C Heat exchanger network / storages Brauwasser- Tank1 85 C Brauwasser- Tank2 85 C 150m³ 150m³ 3000 W85 tank Übertrag BW in KH Reserve Maischen Läutern CIP SH Level [hl] T [ C] KH Res C Vewerfleitungen SH Heißwasser Rückgewinnung aus Brüdenkondensation (Ankochen/Entspannen) Kondensatübertemperatur SH Brüdenkondensat : : : : : : : : :00 Time W85 tank level W85 tank temperature CIP Filtration CIP Heißwasser Für Filtration Abwasser KEG Heißwasser für Flasche/KEG Abwärme Kältemaschinen Verfügbare Speicher Gesamt ~ 80 m³ SOLL T = 65 C FLAHA/KEG WW Kondensatübertemperatur KEG Halle

15 Water storages in the brewery industry

16 Energy storage in the brewery industry (1)

17 Energy storage in the brewery industry (2) Kumulierte Energie (IN - OUT) Wärmeleistung Balancing (IN - OUT) Cumulated energy [MWh] Kumulierte Energie [MJ] Thermal capacity [kw] Wärmeleistung [kw] : : : : : : : : :00 Date/Time

18 Storage concepts technologies useable Use of sensible storages in all sectors of the industry with heating demand under consideration of useful basic conditions Breweries Metal surface treatment industry Food industry Sorption heat storage Waste heat of block type thermal power stations Bakeries, dairies, fruit and vegetable industry Storage of waste use for use in batch processes Bakeries, metal treatment Storage of waste heat from campaign operation Fruit and vegetable industry

19 Storage concepts - strategies Austrian Masterplan for storages Buildings (AEE INTEC) Mobility Smart grids Industry (AEE INTEC) Roadmap for Development of technologies Development of strategies Involvement of international specialists Consulting the Austrian government and the European Commission

20 Storage concepts - tools SOCO Storage Optimisation Concept Development of a software tool Based on a pinch analysis and measured data of installed storages in industry, district heating networks and trade the following targets should be achieved using the SOCO tool: - Design of a heat exchanger network for changing load profiles - Design of a storage system taking the HEN into account - Reduction of the energy demand by increasing the efficiency - Integration of renewable energies esp. solar thermal where technical and economical criteria are full-filled - Design of a holistic optimisation concept and energy saving potentials in complex thermal energy systems - Available for energy auditors, managers, solar designer and plant engineering companies industry, trade, district heating networks with complex heating and cooling streams

21 Storage concepts - challenges Challenges Presentation of the potentials and economic efficiency Storage management Optimised integration of storages (one or more!) in processes and heat exchanger networks Optimised combination of processes Use of the pinch analysis Charging and discharging Design Technology Geometry Internal installations, insulation Temperature layering Combination with renewable energies (solar thermal)

22 Storage concepts - outlook Targets Optimised integration of storages in the production Optimised combination of processes at comparable temperature levels of supplying and demanding processes Reduction of energy (primary) consumption Increase of efficiency Reduction of costs

23 Intelligent storage concepts in the industry Jürgen Fluch AEE Institut for Sustainable Technologies (AEE INTEC) A-8200 Gleisdorf, Feldgasse 19 AUSTRIA