Teknologi for et bedre samfunn
Svenska KVP 2016, Gøteborg, 2016-10-21
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Høytemperatur varmepumper – HeatUp
Petter Nekså[email protected] Energi AS
Also,
Adjunct Professor at NTNU, Dept of Energy and process engineering
Visiting Professor at Doshisha University, Energy Conversion Research Center, Kyoto
Teknologi for et bedre samfunn
Outline of HeatUp
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About the HeatUp project Partners Market and motivation HeatUp goal and focus
Kigali amendment of the Montreal Protocol Basics about high temperature heat pumps Working fluids possibilities Currently focussed activities Example steam MVR Related activities
DRYficiency HighEFF
Conclusions
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HeatUp scope
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Utilisation of surplus heat from industrial processes Surplus heat from 30°C to 50°C and higher Heat pumping for delivery at 80°C to 180°C (250°C)
Solution depending on temperature requirements and energy demand of the industrial processes of the partners
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Focus on efficient energy use and how to meet the increasing energy demand in an environmentally benign wayEnd users: Statoil Oil and gas industry Statkraft Varme District heating Hydro Aluminium Aluminium, producer and supplier of al-products Vedde/TripleNine fish oil- and forage producer Mars Petcare producer of forage, chocolates and beverages TINE SA producer of diary products
Represents three of the largest industry sectors in Norway:Oil and gasMetal productionFood technology
Vendors: Hybrid Energy Cadio AS Epcon Evaporation Technology
KPN project supported by the EnergiX program at RCN (Project no 243679/E20)
Research partners: SINTEF Energy Research NTNU, Energy and process engineering
HeatUp partners
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HeatUpmotivation(Germany)
Reference: Wolf, S., et al. (2014). Universität Stuttgart
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Reference: Wolf, S., et al. (2014). Universität Stuttgart
HeatUpmotivation(Europe)
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HeatUpmotivation
Reference: Wolf, S., et al. (2014). Universität Stuttgart
20-25.000 plants of 1 MW capacity (24/7)Potential 25% of this?
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HeatUp goal and focus
Goal Utilisation of high temperature heat pumps in the
industry to reduce primary energy consumption (el and fossil) reduce greenhouse gas emissions
Reduce dependence of fossil fuels
Focus Satisfy the needs in the partner industries Push heat delivery temperatures to 180'C (250'C) Natural working fluids (HCs, NH3, H2O and CO2)
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HFCs to be phased down according to Kigali amendment
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Natural refrigerants, a long term option, avoiding uncertainty of 4th
generation HFCs (HFOs)
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What COPs can realistically be obtained
Assumptions COP variation with temperature lift and heat absorption temp 60% of Carnot efficiency (COP=ηcarnot× COPcarnot)
0
5
10
15
20 30 40 50 60 70 80 90 100
COP
Temperature lift [K]
120 °C
100 °C
80 °C
60 °C
40 °C
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High temperature heat pump challenges
High discharge temperatures Motor cooling Degradation of lubricant, if not oil-free Suction temperatures often above ambient temperatures Acceptable temperature lifts, available heat sources Adaptation to actual heat source and sink characteristics Heat exchange with demanding fluids under challenging
conditions Cost competition to alternative means of heat supply
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Simplified comparison of fluids
*Evaporating enthalpy and thermal conductivity
Property Water Ammonia Propane Butane Isobutane Pentane CO2 R134a R1234yf
Critical temperature 374 132 97 152 135 197 31 101 95
Normal boiling point 100 -33 -42 0 -12 36 - -26 -29
Specific volume Very high
Thermal properties* Very good Good
Safety
Environmental impact
Price
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Propane – butane cascade heat pump Water heating to 120'C
Steam - water MVR – steam up to 150'C for drying
Ammonia – water District heating utilising a high
temperature absolute heat source
Currently focussed activities
Wet product
Steam
Drying system
Direct or
indirect
Dry product
Excess vapour
Condensate / cold steam
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Wet product
Steam
Drying system
Direct or
indirect
Dry product
Excess vapour
Condensate / cold steam
Re-heating of steam
Drying system
Direct or
indirect Condensate / cold steam
Steam
(Oil, gas or electricity)
Excess vapour
Example – MVR steam based drying system
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Example – MVR steam based drying system
Use excess vapour as heat sourceNeed to compress it to a higher pressure level (= higher
temperature level for condensing) Re-heating of process steam to initial conditions Reduce the specific energy consumption from 0.8 to 0.2 kW per
kgwater
Energy saving potential of up to 80% Electricity to run the compressors is the main primary energy
input into the system MVR-concept is well known and established Return of investment depends on energy prices and system
cost
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Compression Technology for MVR systems
Type Compressor Turbocompressor Centrifugal Fan Roots Air Blower
Pressure Ratio (single stage)
<5 <2 ≤ 1.3 ≤ 1.5
Temperature Rise Single stage max. 40 °C
Single Stage max. 20℃
Single Stage max.7℃ Single Stage max.~10℃
Max. Flow Rate 120 t/h 100 t/h 120 t/h 3~5 t/hImpeller Type Screw or piston
compressor Three-dimension Flow, Centrifugal Type
Two-dimension Flow, Centrifugal Type
Two-impeller or Three-impeller, Volume Type
Impeller Material Stainless Steel Stainless Steel or Titanium Steel
Stainless Steel Cast Iron, Nickel Plating or Nickel-Phosphorus
Manufacturing Cost High High (medium?) Low Quite LowPhotos
Realization of Rotary Speed
Direct or gear drive Gear Increase Direct Connection with High-speed Motor
Synchronous Gear
Range of Rotary Speed
Commonly less than 4000 r/min
5000~40000r/min Commonly less than4000r/min
150~3000r/min
Thin Oil Lubricating System
Yes, oil separator necessary
Yes, Not Contacted with Medium at all
Unavailable for the Majority
Gear Oil and Grease Lubrication, Contacted with Medium
Service Life 5 years Three-year Three-year Nearly One Year
Overview of available compression technology for steam compression (MVR)
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Turbo-charger for Superheated Steam: Pressure ratio 2.4 per stage; Temperature increase from 100 to 150 °C, about
25K per stage Swept volume is 0.2 m3/s Speed: rpm up to 86000 Volumetric efficiency 0.7 - 0.8 Isentropic efficiency 0.8 Specific weight: 20 kWheat / kgmetal
Alternative technologies: Screw compressors (1 stage) "Roots" blower + fan for SHS (5 stage)
New Compressor Technology
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Compressor efficiency map
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Used prim. energy, kW
Steam regeneration, kW
Excessheat, kW
COP total, -
COP steam, -
DryingefficiencykWh kg-1
Traditional scheme (oil)
1638.6 1556.6 1542.6 1.89? 0.95 0.79
Open system(HP)
405.4 1556.6 371.0 4.75 3.84 0.19
Closed system(HP)
470.2 1556.6 406.5 4.17 3.31 0.22
Example: MVR system (3 stage MVR 100-180°C)
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Case 1 Germany
Case 1 Norway
Case 2 Germany
Case 2 Norway
Pressure Inlet Bara 1.0 1.0 1.0 1.0Temperature Inlet Deg C 110 110 110 110Pressure Outlet Bara 5.0 5.0 10.0 10.0Steam Flow Rate (inlet)
kg/h 2,000 2,000 2,000 2,000
Electrical Power (system)
kWe 304 304 461 461
Heat Recovered kWt 1,430 1,430 1,552 1,552COP W/W 4.70 4.70 3.36 3.36Net Savings p.a. € p.a. 143k 755k 0 744kEstimated payback ≈ 3 years ≈ 1 year NA 1 – 2 years
Case 1: MVR to 150°C Case 2: MVR to 180°C
compressor, motor, inverter drive, instrumentation & control, auxiliaries and ancillaries
Example: MVR system return on investment
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DRYficiency – EU project
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HighEFF, Research Center on Energy efficiency in the industry
Corner Stones: Energy Efficient
Processing Surplus Heat Utilization Industrial Clusters Education and Training
Research Areas: Methodologies Components Cycles Applications Society Case Studies
About 50 national and international partners Budget 420 MNOK over 8 years (2016-2024)
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Large amounts of heat supply in the industry can be provided by high temperature heat pumps (HTHP)
HTHPs can reduce primary energy consumption and reduce emissions of greenhouse gases
Operating conditions may be very challenging Natural working fluid alternatives exist Systems and components are under development in the
HeatUp project and other projects
Thank you very much!
Conclusions
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HeatUp more information
Contacts:[email protected]@sintef.no
http://www.sintef.no/projectweb/heatup/
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