Combustion irreversibilities: Numerical simulation and analysis

An exergy analysis was performed considering the combustion of methane and agro-industrial residues produced in Portugal (forest residues and vines pruning). Regarding that the irreversibilities of a thermodynamic process are path dependent, the combustion process was considering as resulting from different hypothetical paths each one characterized by four main sub-processes: reactant mixing, fuel oxidation, internal thermal energy exchange (heat transfer), and product mixing. The exergetic efficiency was computed using a zero dimensional model developed by using a Visual Basic home code. It was concluded that the exergy losses were mainly due to the internal thermal energy exchange sub-process. The exergy losses from this sub-process are higher when the reactants are preheated up to the ignition temperature without previous fuel oxidation. On the other hand, the global exergy destruction can be minored increasing the pressure, the reactants temperature and the oxygen content on the oxidant stream. This methodology allows the identification of the phenomena and processes that have larger exergy losses, the understanding of why these losses occur and how the exergy changes with the parameters associated to each system which is crucial to implement the syngas combustion from biomass products as a competitive technology.     

Energy conservation with tumbler drying in laundries

While the energy consuming process of drying paper, textiles and construction materials during manufacturing has warranted a large number of studies, the more dispersed everyday activity of laundry drying seems not to have awakened as much interest. This is perhaps because laundry drying installations are usually either domestic or comparatively small. Nevertheless, the energy used for laundry drying represents 0.5% of the total electrical energy use in Switzerland for example, and that figure is bound to be still higher in other countries. In this article it is demonstrated that conventional tumbler dryer technology is susceptible to improvement by the use of heat recovery heat exchangers. The energy recovery potential may be as high as 20% of that required for heating the drying air. The additional investment required for the heat recovery heat exchanger is paid back in less than two years of normal use.     

An exergy analysis on the performance of a counterflow wet cooling tower

Cooling towers are used to extract waste heat from water to atmospheric air. An energy analysis is usually used to investigate the performance characteristics of cooling tower. However, the energy concept alone is insufficient to describe some important viewpoints on energy utilization. In this study, an exergy analysis is used to indicate exergy and exergy destruction of water and air flowing through the cooling tower. Mathematical model based on heat and mass transfer principle is developed to find the properties of water and air, which will be further used in exergy analysis. The model is validated against experimental data. It is noted from the results that the amount of exergy supplied by water is larger than that absorbed by air, because the system produces entropy. To depict the utilizable exergy between water and air, exergy of each working fluid along the tower are presented. The results show that water exergy decreases continuously from top to bottom. On the other hand, air exergy is expressed in terms of convective and evaporative heat transfer. Exergy of air via convective heat transfer initially loses at inlet and slightly recovers along the flow before leaving the tower. However, exergy of air via evaporative heat transfer is generally high and able to consume exergy supplied by water. Exergy destruction is defined as the difference between water exergy change and air exergy change. It reveals that the cooling processes due to thermodynamics irreversibility perform poorly at bottom and gradually improve along the height of the tower. The results show that the lowest exergy destruction is located at the top of the tower.     

Energy harvesting, reuse and upgrade to reduce primary energy usage in the USA

Two-thirds of input energy for electricity generation in the USA is lost as heat during conversion processes. Additionally, 12.5% of primary fuel and 20.3% of electricity are employed for space heating, water heating, and refrigeration where low-grade heat could suffice. The potential for harnessing waste heat from power generation and thermal processes to perform such tasks is assessed. By matching power plant outlet streams with applications at corresponding temperature ranges, sufficient waste heat is identified to satisfy all USA space and water heating needs. Sufficient high temperature exhaust from power plants is identified to satisfy 27% of residential air conditioning with thermally activated refrigeration, or all industrial refrigeration and process heating from 100 to 150 °C. Engine coolant and exhaust is sufficient to satisfy all air conditioning and 68% of electrical demands in vehicles. Overall, this study demonstrates the potential to reduce USA primary energy demand by 12% and CO₂ emissions by 13% through waste heat recovery. A detailed analysis of thermal energy demand in pulp and paper manufacturing is conducted to demonstrate the methodology for improving the fidelity of this approach. These results can inform infrastructure and development to capture heat that would be lost today, substantially reducing USA energy intensity.     

Heat Exchangers as Equipment and Integrated Items in Waste and Biomass Processing

Heat recovery systems play an important role in waste to energy and biomass processing. An efficient approach that follows a recommended hierarchy in design, process as a whole (e.g., incineration) → subsystem of the process (e.g., heat recovery system) → equipment (e.g., air pre-heater), is shown. Important factors have to be taken into consideration in processes for incineration (combustion of biomass), especially available energy, specific features of hot process fluid (flue gas), type of waste/biomass, fouling, and environmental impact. A combination of intuitive design, know-how, and a sophisticated approach based on up-to-date computational tools is shown. Some novel types of heat exchangers (e.g., air preheaters for high- and low-temperature applications, heat recovery steam generators and/or heaters, and those for specific applications) that can be substituted for conventional ones are presented. An improved or even optimum design of heat exchangers requires computational support in the following areas: a simulation based on energy and mass balance, the thermal and hydraulic calculation of heat exchangers, a CFD (computational fluid dynamics) approach, optimization, and heat integration. Some examples are presented. An approach that ranges from an idea to an industrial application is demonstrated on the novel design of integrated compact equipment (combustion chamber installed inside heat exchanger) for the thermal treatment of waste gases, including heat recovery. This approach involves simulation for obtaining basic process parameters, thermal and hydraulic calculations, design of experimental facility, the manufacture of the equipment and building of this facility, operation and functionality testing, data acquisition for validating and improving the CFD model, and the utilization of feedback from industrial applications.     

Energy recovery from high temperature slags

Molten slags represent one of the largest untapped energy sources in metal manufacturing operations. The waste heat of slags amounting to ∼220 TWh/year at temperatures in the range of 1200–1600 °C, presents an opportunity to lower the energy intensity of metal production. Currently, three types of technologies are under development for utilizing the thermal energy of slags; recovery as hot air or steam, conversion to chemical energy as fuel, and thermoelectric power generation. The former route is most developed with its large scale trials demonstrating recovery efficiencies up to 65%. The latter two are emerging as the next generation methods of waste heat recovery. An evaluation of these methods shows that for both thermal and chemical energy recovery routes, a two-step process would yield a high efficiency with minimal technical risk. For thermoelectric power generation, the use of phase change materials appears to solve some of the current challenges including the mismatch between the slag temperature and operating range of thermoelectric materials.     

Thermodynamic modeling of an integrated biomass gasification and solid oxide fuel cell system

An integrated process of biomass gasification and solid oxide fuel cells (SOFC) is investigated using energy and exergy analyses. The performance of the system is assessed by calculating several parameters such as electrical efficiency, combined heat and power efficiency, power to heat ratio, exergy destruction ratio, and exergy efficiency. A performance comparison of power systems for different gasification agents is given by thermodynamic analysis. Exergy analysis is applied to investigate exergy destruction in components in the power systems. When using oxygen-enriched air as gasification agent, the gasifier reactor causes the greatest exergy destruction. About 29% of the chemical energy of the biomass is converted into net electric power, while about 17% of it is used to for producing hot water for district heating purposes. The total exergy efficiency of combined heat and power is 29%. For the case in which steam as the gasification agent, the highest exergy destruction lies in the air preheater due to the great temperature difference between the hot and cold side. The net electrical efficiency is about 40%. The exergy combined heat and power efficiency is above 36%, which is higher than that when air or oxygen-enriched air as gasification agent.     

Analysis of a molten carbonate fuel cell: cogeneration to produce electricity and cold water

The fuel cell is an emerging cogeneration technology that has been applied successfully in Japan, the USA and some countries in the European Union. This system performs direct conversion of the chemical energy of the oxidation of hydrogen from fuel with atmospheric oxygen into direct current electricity and waste heat via an electrochemical process relying on the use of different electrolytes (phosphoric acid, molten carbonate and solid oxide, depending on operating temperature). This technology permits the recovery of waste heat, available from 200°C up to 1000°C depending on the electrolyte technology, which can be used in the production of steam, hot or cold water, or hot or cold air, depending on the associated recuperation equipment. In this paper, an energy, exergy and economic analysis of a fuel cell cogeneration system (FCCS) is presented. The FCCS is applied in a segment of the tertiary sector to show that it is a feasible alternative for rational decentralized energy production under Brazilian conditions. The technoeconomic analysis shows a global efficiency or fuel utilization efficiency of 86%. Analysis shows that the exergy losses in the fuel cell unit and the absorption refrigeration system are significant. Furthermore, the payback period estimated is about 3 and 5 years for investments in fuel cells of 1000 and 1500 US$/kW, respectively.     

High-efficiency power production from natural gas with carbon capture

A unique electricity generation process uses natural gas and solid oxide fuel cells at high electrical efficiency (74%HHV) and zero atmospheric emissions. The process contains a steam reformer heat-integrated with the fuel cells to provide the heat necessary for reforming. The fuel cells are powered with H₂ and avoid carbon deposition issues. 100% CO₂ capture is achieved downstream of the fuel cells with very little energy penalty using a multi-stage flash cascade process, where high-purity water is produced as a side product. Alternative reforming techniques such as CO₂ reforming, autothermal reforming, and partial oxidation are considered. The capital and energy costs of the proposed process are considered to determine the levelized cost of electricity, which is low when compared to other similar carbon capture-enabled processes.     

Energetic and exergetic performance analyses of a combined heat and power plant with absorption inlet cooling and evaporative aftercooling

In this paper, exergy method is applied to analyze the gas turbine cycle cogeneration with inlet air cooling and evaporative aftercooling of the compressor discharge. The exergy destruction rate in each component of cogeneration is evaluated in detail. The effects of some main parameters on the exergy destruction and exergy efficiency of the cycle are investigated. The most significant exergy destruction rates in the cycle are in combustion chamber, heat recovery steam generator and regenerative heat exchanger. The overall pressure ratio and turbine inlet temperature have significant effect on exergy destruction in most of the components of cogeneration. The results obtained from the analysis show that inlet air cooling along with evaporative aftercooling has an obvious increase in the energy and exergy efficiency compared to the basic gas turbine cycle cogeneration. It is further shown that the first-law efficiency, power to heat ratio and exergy efficiency of the cogeneration cycle significantly vary with the change in overall pressure ratio and turbine inlet temperature but the change in process heat pressure shows small variation in these parameters.     

Exergy analysis on the irreversibility of rotary air preheater in thermal power plant

Energy recovery devices can have a substantial impact on process efficiency and their relevance to the problem of conservation of energy resources is generally recognized to be beyond dispute. One type of such a device, which is commonly used in thermal power plants and air conditioning systems, is the rotary air preheater. A major disadvantage of the rotary air preheater is that there is an unavoidable leakage due to carry over and pressure difference. There are gas streams involved in the heat transfer and mixing processes. There are also irreversibilities, or exergy destruction, due to mixing, pressure losses and temperature gradients. Therefore, the purpose of this research paper is based from the second law of thermodynamics, which is to build up the relationship between the efficiency of the thermal power plant and the total process of irreversibility in the rotary air preheater using exergy analysis. For this, the effects of the variation of the principal design parameters on the rotary air preheater efficiency, the exergy efficiency, and the efficiency of the thermal power plant are examined by changing a number of parameters of rotary air preheater. Furthermore, some conclusions are reached and recommendations are made so as to give insight on designing some optimal parameters.     

Two novel oxy-fuel power cycles integrated with natural gas reforming and CO2 capture

Two novel system configurations were proposed for oxy-fuel natural gas turbine systems with integrated steam reforming and CO₂ capture and separation. The steam reforming heat is obtained from the available turbine exhaust heat, and the produced syngas is used as fuel with oxygen as the oxidizer. Internal combustion is used, which allows a very high heat input temperature. Moreover, the turbine working fluid can expand down to a vacuum, producing an overall high-pressure ratio. Particular attention was focused on the integration of the turbine exhaust heat recovery with both reforming and steam generation processes, in ways that reduce the heat transfer-related exergy destruction. The systems were thermodynamically simulated, predicting a net energy efficiency of 50–52% (with consideration of the energy needed for oxygen separation), which is higher than the Graz cycle energy efficiency by more than 2 percentage points. The improvement is attributed primarily to a decrease of the exergy change in the combustion and steam generation processes that these novel systems offer. The systems can attain a nearly 100% CO₂ capture.     

Investigation of soot transport and radiative heat transfer in an ethylene jet diffusion flame

Numerical and experimental investigations highlighting the heat and mass transfer phenomena in a laminar co-flowing jet diffusion flame have been carried out. The fuel under consideration is ethylene, with ambient air as the co-flowing oxidizer. The diffusion flame is modeled using a 17-step reduced reaction mechanism with finite rate chemistry and the effects of soot on the radiative heat transfer of the flame have been demonstrated. Soot growth and oxidation processes are studied using a two-equation transport model, while the radiative heat transfer is modeled using the P1 approximation. An in-house finite volume code has been developed to solve the axi-symmetric Navier–Stokes equations in cylindrical coordinates, along with the soot mass fraction, soot number density, energy and species conservation equations. Comparison of predictions with experimental results shows reasonable agreement with regard to the flame height and temperature distribution. A parametric study is also presented, which illustrates the effects of the fuel jet Reynolds number and the flow rate of co-flow air.     

Targeting for energy efficiency and improved energy collaboration between different companies using total site analysis (TSA)

Rising fuel prices, increasing costs associated with emissions of green house gases and the threat of global warming make efficient use of energy more and more important. Industrial clusters have the potential to significantly increase energy efficiency by energy collaboration. In this paper Sweden’s largest chemical cluster is analysed using the total site analysis (TSA) method. TSA delivers targets for the amount of utility consumed and generated through excess energy recovery by the different processes. The method enables investigation of opportunities to deliver waste heat from one process to another using a common utility system.The cluster consists of 5 chemical companies producing a variety of products, including polyethylene (PE), polyvinyl chloride (PVC), amines, ethylene, oxygen/nitrogen and plasticisers. The companies already work together by exchanging material streams. In this study the potential for energy collaboration is analysed in order to reach an industrial symbiosis. The overall heating and cooling demands of the site are around 442 MW and 953 MW, respectively. 122 MW of heat is produced in boilers and delivered to the processes.TSA is used to stepwise design a site-wide utility system which improves energy efficiency. It is shown that heat recovery in the cluster can be increased by 129 MW, i.e. the current utility demand could be completely eliminated and further 7 MW excess steam can be made available. The proposed retrofitted utility system involves the introduction of a site-wide hot water circuit, increased recovery of low pressure steam and shifting of heating steam pressure to lower levels in a number heat exchangers when possible. Qualitative evaluation of the suggested measures shows that 60 MW of the savings potential could to be achieved with moderate changes to the process utility system corresponding to 50% of the heat produced from purchased fuel in the boilers of the cluster.Further analysis showed that after implementation of the suggested energy efficiency measures there is still a large excess of heat at temperatures of up to 137 °C.     

An ammonia energy vector for the hydrogen economy

This paper proposes the use of ammonia as a multipurpose energy vector. Synthesized from hydrogen produced in a large, centralized facility using nuclear process heat from a high-temperature, gas-cooled reactor (HTGR), the ammonia serves as a low-cost vehicle for energy storage and transmission, via pipeline, to remote demand centers where some of it serves as a clean-burning fuel for local cogeneration and process heat applications, and some of it is used for direct agricultural application or as feedstock for production of nitrogen-based fertilizers or other chemical processes.     

Comparison study on different ITM‐integrated MCFC hybrid systems with CO2 recovery using sweep gas

Previous study shows the ITM (oxygen ion transfer membrane)‐integrated MCFC (molten carbonate fuel cell) hybrid system with CO₂ recovery can maintain high efficiency; however, the oxygen partial pressure on the ITM permeate side is usually 1 atm, which requires a very high pressure ratio of the ITM air compressor in order to separate the oxygen; using the sweep gas can solve this problem. In this paper the ITM‐integrated MCFC hybrid systems with CO₂ recovery using different sweep gases are studied. With the Aspen plus software, two systems with different sweep gases are established, and their performances are compared with the benchmark system without sweep gas; the effects of key parameters on the optimum system performance are also investigated. Results show that compared with the benchmark system, the efficiencies of the systems with sweep gases are increased and the pressure ratios of the air compressors are decreased; the system using pure CO₂ as sweep gas can improve the system efficiency by 1.25%, which is superior to the system using the mixture gas of CO₂ and H₂O as sweep gas. Achievements from this paper will provide a valuable reference for CO₂ recovery from the MCFC hybrid power system with lower energy consumption. Copyright © 2016 John Wiley & Sons, Ltd.     

Energy efficiency improvement of dryer section heat recovery systems in paper machines – A case study

Modern paper machines are equipped with heat recovery systems that transfer heat from the humid exhaust air of the paper machine’s dryer section to different process streams. As a result of process changes, the heat recovery systems may operate in conditions far from the original design point, creating a significant potential for energy efficiency improvement. In this paper we demonstrate this potential with a case study of three operating paper machines. Both operational and structural improvement opportunities are examined. Since the existing retrofit methodologies for heat exchanger networks can not be applied to cases with condensing air, we use thermodynamic simulation models presented earlier to assess the effects of possible changes on the existing heat recovery systems. In order to reduce the required processing time of the simulation models, only a limited number of pre-screened retrofit designs are considered. The pre-screening is carried out on the basis of guidelines presented earlier. The analysis in the case mill revealed savings of 110 GWh/a in process heat with profitable investments. According to the follow-up study, the investments carried out have resulted in 12% lower fuel use and 24% lower CO₂ emissions. The results imply that all operating paper machines should be similarly examined.     

Design of water and heat recovery networks for the simultaneous minimisation of water and energy consumption

This paper describes procedures for the design of processes in which water and energy consumption form a large part of the operating cost. Good process design can be characterised by a number of properties, amongst the most important are: efficient use of raw materials, low capital cost and good operability.In terms of thermodynamic analysis these processes can be characterised as being either a “pinch” problem or a “threshold” problem. This paper concentrates on developing designs for problems of the threshold type. Most of the problems discussed by previous workers have been of this type. With these properties in mind this work looks at the design of integrated water and energy systems that exhibit the following features: 1. minimum water consumption, 2. minimum energy consumption, and 3. simple network structure. The approach applies for single contaminant.It is shown that the water conservation problem and the heat recovery problems can be de-coupled and the water conservation options should be established first. It is then shown that the number of heaters and heat recovery units required for the system, the quantity and type of hot utility needed for the plant and the complexity of the heat recovery network can all be determined without having to design any heat recovery network. This allows the engineer to select the better water conservation option before embarking on the design of the heat recovery network. For this type of problem the design of the heat recovery network itself is usually simple and straightforward.