Final Report Summary - ICARUS (An Innovative, environmentally friendly CO2/Lubricant Absorption Power System for Highly efficient Power Generation from Low Temperature industrial waste heat to reduce emissions and costs.) Executive Summary:The aim of the ICARUS project was to create an absorption power generation technology for low temperature (60-120oC) heat. This would then enable a waste-heat power generation system for industrial (chemical, cement etc.) applications to be created that can generated electricity from industrial waste heat (<120oC) without affecting industrial processes. By doing this, the absorption power generation system created will offer greatly improved environmental performance due to improved efficiency and reduced CO2 emissions at a cost that is affordable to the end-user. This will lead to significant economic and societal benefits to manufacturers.An initial system specification was generated along with a mathematical thermodynamic model for the ICARUS absorption system. A literature search of potential working fluids was carried out and POE32/C02 was selected for further investigation. The predicted system efficiency was found to be inadequate and consequently it was decide to investigate a pure C02 system. Although the system efficiency of this was calculated to improve, the operating pressure was much higher and the associated potential system costs thought too great. Therefore a selected new refrigerant Organic Rankine Cycle (ORC) power generation system was investigated. A small scale 5kW prototype system based on the refrigerant was designed and constructed incorporating a selected expander. This was then tested. Although the performance was lower than predicted possible reasons were identified and a set of recommendations to improve the system efficiency proposed.An economic and environmental analysis of the ICARUS system based on the laboratory results and recommendation s for improvement was carried out. This indicated that for a commercial 20 kW unit the pay-back time for a prospective user would be considered commercially attractive. In addition this unit would reduce CO2 emissions by 88.12 tonnes in the UK and 124.45 tonnes in Greece. The main result of the project is a design for a 20kW ORC based absorption system with potential commercial viability if certain technical issued can be successfully resolved. Consequently it is considered a strong basis for a follow up project to create a demonstration unit that can be easily and quickly commercialised on completion.No Intellectual Property Rights (IPR) in terms of patent applications have been identified, however, the know-how generated during the project will be invaluable for the proposed follow up projectProject Context and Objectives:The EU manufacturing sector is vitally important to the EU economy, contributing ~17.1% of GDP and accounted for some 22 million jobs (2007). EU exports have expanded by 4.7% p.a. over 2000-2008 and in some sectors the EU has increased its share of world exports between 1996 and 2006, notably in chemicals, pharmaceuticals, and motor vehicles. SMEs represent 99% of the EU manufacturing sector equating to over 2.An initial system specification was generated along with a mathematical thermodynamic model for the ICARUS absorption system. A literature search of potential working fluids was carried out and POE32/C02 selected for further investigation in the laboratory then subsequent development work in terms of modelling. Also a suitable expander was identified for use within the proposed system.The predicted system efficiency for the POE32/C02 was found to be inadequate and consequently it was decide to investigate a pure C02 system. Although the system efficiency of this was calculated to improve, the operating pressure was much higher and the associated potential system costs thought too great. Consequently a selected new refrigerant ORC power generation system was investigated and modelled. Consequently a new expander was sourced.A small scale 5kW prototype system based on the refrigerant was designed and constructed incorporating the selected expander. This was then tested in the laboratory. Although the performance was lower than predicted possible reasons were identified and a set of recommendations to improve the system efficiency proposed.The main result of the project is a design for a 20kW ORC based power genaration system with potential commercial viability if certain technical issued can be successfully resolved. Consequently it is considered a strong basis for a follow up project to create a demonstration unit that can be easily and quickly commercialised on completion.No Intellectual Property Rights (IPR) in terms of patent applications have been identified, however, the know-how generated during the project will be invaluable for the follow up project.5 million companies. As manufacturing is resource intensive both in terms of raw materials and energy consumption, despite rising costs (energy and raw materials) SMEs are under increasing threat to remain competitive against non-EU based companies.The aim of the ICARUS project is to create an absorption power generation technology for low temperature (60-120oC) heat. This will enable us to create a waste-heat power generation system for industrial (chemical, cement etc.) applications that can achieve an efficiency of up to 20% for electricity to be generated from industrial waste heat (less than 120oC) without affecting industrial processes. By doing this, the absorption power generation system created will offer greatly improved environmental performance due to improved efficiency and reduced CO2 emissions at a cost that is affordable to the end-user. This will lead to significant economic and societal benefits to manufacturers. The SME consortium will target up to 10 % of the EU manufacturing SMEs operating within the Chemicals and Cement Industry within a 5 year period, thus achieving direct estimated annual sales of over €100 million, ~700 new jobs and thus helping manufacturing SMEs to make annual average CO2 emissions savings of up to 4,000 t p.a. per company.Project Results:An initial system specification was generated along with a mathematical thermodynamic model for the ICARUS absorption system. A literature search of potential working fluids was carried out and POE32/C02 selected for further investigation in the laboratory then subsequent development work in terms of modelling. Also a suitable expander was identified for use within the proposed system.The predicted system efficiency for the POE32/C02 was found to be inadequate and consequently it was decide to investigate a pure C02 system. Although the system efficiency of this was calculated to improve, the operating pressure was much higher and the associated potential system costs thought too great. Consequently a selected new refrigerant ORC power generation system was investigated and modelled. Consequently a new expander was sourced.A small scale 5kW prototype system based on the refrigerant was designed and constructed incorporating the selected expander. This was then tested in the laboratory. Although the performance was lower than predicted possible reasons were identified and a set of recommendations to improve the system efficiency proposed.The main result of the project is a design for a 20kW ORC based power genaration system with potential commercial viability if certain technical issued can be successfully resolved. Consequently it is considered a strong basis for a follow up project to create a demonstration unit that can be easily and quickly commercialised on completion.No Intellectual Property Rights (IPR) in terms of patent applications have been identified, however, the know-how generated during the project will be invaluable for the follow up project.Potential Impact:From an economic perspective implementation and commercialisation of this technology will help the SME participants to achieve sustainable and profitable business growth. This will be achieved from (1) their specific activities within the supply chain which will lead to increased sales and profits; (2) their IPR ownership for a range of new products which will enable each SME to expand its company product portfolio and/or license (or sub-contract) the technology including for other applications; (3) the specific knowledge acquired as a result of their participation in the project will allow them to gain deeper integration within the supply chain R&D activities. In addition the technology has potential for other energy recovery from waste heat applications. Potential end-user sectors could include: heavy duty vehicles, rail, marine and large scale solar heat plants. In terms of the environment implementation and commercialisation of this technology in the identified end-users sectors will have a positive impact through improved fuel efficiency and thereby reduced CO2 emissions. For example, the envisaged commercial 20 kW unit is expected to reduce annual CO2 emissions by 88.12 tonnes in the UK and 124.45 tonnes in Greece. This is a significant amount and would deliver a huge benefit to the environment across Europe.The main dissemination activities have centred particularly on the project and partner websites. The latter containing a link to the former to increase visits. The project website contains a news section which has been regularly updated with information on project activities and outcomes. In addition a project video, including all partners, has been produced and uploaded to the Co-ordinator YouTube channel. It is also available for partners to upload to their own media channels.A Wikipedia page has been produced to add to the credibility of the project with the aim to increase exposure of the project and help reach the widest audience. The article will stay in place indefinitely and will increase the exposure of the project on the internet, it can be edited further to add results and information on a second project. Publications have included articles in a scientific newsletter, a news item related to an international conference on sustainable energy and a trade association website.No Intellectual Property Rights (IPR) in terms of patent applications have been identified, however, the know-how generated during the project will be invaluable for a proposed follow up project. This project will generate IPR in its own right.List of Websites:www.icaruspower.euICARUS is managed by European Thermodynamics Ltd from its office in Kibworth, Leicestershire, UK To contact the ICARUS Project Manager then use the online form or directly via the contact numbers below:Telephone: +44 (0)116 279 6899Fax: +44 (0)116 279 3490
