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TASIO Report Summary

Project ID: 637189
Funded under: H2020-EU.3.3.1.

Periodic Reporting for period 1 - TASIO (Waste Heat Recovery for Power Valorisation with Organic Rankine Cycle Technology in Energy Intensive Industries)

Reporting period: 2014-12-01 to 2016-05-31

Summary of the context and overall objectives of the project

TASIO project is devoted to the recovery and reuse of waste heat produced in Energy Intensive Industries (EII) through the development of the Organic Rankine Cycle (ORC) technology incorporating the direct heat exchange concept. The main aim is to develop a multisectorial technology that can be used in EII such as cement, glassmaking, steelmaking and petrochemical companies and set up a demonstrator in one industrial site to validate the developed concepts.

The final solution will be designed after an evaluation of the energetic situation of these four industrial sectors and will be based on the development of Waste Heat Recovery Systems (WHRS) based on the ORC technology. This technology is able to recover and transform the thermal energy of the flue gases of EII into electric power for internal or external use. In the direct exchange concept heat from the flue gases is directly put in contact with the organic fluid of the ORC system. The conventional step of exchanging this heat with a thermal fluid located before the ORC is eliminated with the aim of increasing the yield of the process and reducing the cost of installation and maintenance. Furthermore, the project will also evaluate the possibility of using the conventional ORC process to recover and transform the energy of the flue gases of EII into mechanical energy for internal use (air compressors).
In order to achieve these results different technical challenges will have to be approached. On the one hand a study on the materials and coatings that will be in contact with the flue gases will be completed, alternatives to currently used conventional steels will be identified and proposed that may withstand the high temperatures and corrosive features of the flue gases. The tasks will be further completed by the design of a new integrated monitoring and control system for the addressed sectors. Last but not least the modeling of the flow of the flue gases within the ORC heat exchanger will be approached in order to foresee the flow rate, temperature distribution and effect of particulates with the different flue gases to be analysed.
The consortium formed to carry out the project consists of 8 partners from 3 European countries. They cover several relevant sectors of the energy intensive industry, namely cement, steel, glass and petrochemical sectors. The industrial involvement in the project is significant and the project addresses the implementation of a full demonstration of the WHRS for electrical energy generation in the cement producer facilities as well as a semi-validation of the WHRS for air compressors energy supply system at pilot scale.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The report contains the description of the work and results corresponding to the first 18 months of the project. In general terms the project has followed the initial plan and does not present any substantial delay so far. Following the main aspects approached in each of the technical workpackages is described.

WP2 Evaluation of heat recovery potentials in EII.
The aim of this workpackage was to analyse the processes and subprocesses of the four industrial sectors selected from the point of view of the flue heat recovery potential. This task has been finished on time and the corresponding deliverables D2.1 Energetic flowchart for each sector and D2.2 Heat recovery potentials in the most demanding processes have been produced. The responsible of this workpackage has been GERDAU, the partner representing the steelmaking industry and all the rest of industrial participants have collaborated by providing the details of each corresponding sector. The main conclusions obtained are that the potential of the plants for energy savings is enormous and it is estimated that somewhere between 20 to 50% of industrial energy input is lost as waste heat in the form of hot exhaust gases, cooling water, and heat lost from hot equipment surfaces and heated products. Furthermore the most suitable waste heat sources that could be exploited for electricity production have been identified in each of the four sectors analysed. In the case of a steelmaking plant the exploitation of these sources for electricity production could lead to a significant energy recovery: a net electricity production between 565 and 1,870 kW is found to be possible in the specific plants taken as a reference.

WP3 Development of a new generation of ORC turbogenerators
The objective of this WP was to develop the theoretical concept of the multisectorial ORC turbogenerator with the direct heat exchange concept incorporated. The workpacakge is finished and the four technical reports associated with it include the list and analysis of the requirements of the ORC turbogenerator for EII Processes, the analysis of materials and coatings for the heat exchanger. Different models of the flow behaviour in the heat exchanger corresponding to the glassmaking industry case and eventually technical data and drawings of the developed heat exchanger

WP4Advanced monitoring & control systems
The new WHRS concept requires different monitoring and control systems that may account for the new process conditions that the ORC equipment must withstand derived from the direct contact of hot (300-450ºC) and corrosive dusty flue gases coming from the flue gases of the mentioned industrial processes. During the first 18 months of the project and based on the information collected in WP2 and WP3 related to the nature and features of the different flue gases new sensors and actuators have been identified that may be used to monitor the system. Furthermore the report on the Performance and Predictive Tools Analysis has been finished. The next tasks of this WP will be directly related to the description of the specifications of the technology to be developed.

WP5 Design and integration of the waste heat recovery system
The WP5 started in month 13 as planned following the conclusion of previous tasks where the required information on the specific demonstrator to be built was collected. During these first 6 months TURBODEN has finished and reported the Preliminary design of the WHRS based on the new ORC concept and the theoretical validity of the design has been confirmed. In the following months this task will be completed with simulation of the whole ORC performance and final design of the WHRS that is planned to be finished before the end of 2016.

WP6 Design and concept validation of the WHRS for air compressors Energy supply
This WP is focused on the study of a second concept within the project. The expected TRL is lower than that to be achieved in the development of the direct heat exchanger concept and the final aim is to validate the concept of the use of WHRS for the production of compressed air with conventional ORC equipment. The work began in month 13 as planned in the amended version of the Document of the action (DoA) and during these first six months the design of the WHRS to transform recovered heat into mechanical energy has been finished and the corresponding report has been shared among the consortium. The next step to be approached in 2016 will be the set up of the transmission system, adaptation of the pilot ORC equipment and demonstration and validation of the concept at pilot plant scale trials.

WP7 Validation and demonstration of the WHRS in Real Production conditions.
The tasks corresponding to the demonstration trials have just begun (with the analysis of the adaptation of the existing industrial plant. Technical and economic aspects have been studied for the setting up and demonstration activities to be carried out in the last part of the project.

WP9: Dissemination, exploitation and IPR strategies.
During the first 18 months the work has been rather focused on the setting up of the TASIO project website and the preparation of dissemination materials (posters, leaflets etc.). Different participants have attended workshops and meetings where the conceps to be developed and the expected results have been explained. Furthermore the first two versions of the Dissemination and Communication plan have been made available.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

In the first 18 months the following aspects that are beyond the current state of the art have been developed:
Concepts of he direct heat exchanger concept linked to the ORC for the reuse of the heat of flue gases for the production of electricity and the use of the ORC technology for the production of compressed air. Development of the concept design of the multisectorial heat exchanger that may be used in different EII sectors and processes and subprocesses. There has not been any actual impact yet in terms of socio-economic aspects as it is too early to have exploitable results in the project but the potential impact foreseen in the DoA have been confirmed in the analysis and studies carried out so far in the project.

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