Periodic Reporting for period 1 - ZiGrid Technology (Shifting Waste Heat from Problem to Power)
Reporting period: 2024-03-01 to 2025-02-28
ZIGRID Project: EIC Project Summary for EIC Portal
Context and Overall Objectives
At the heart of the ZIGRID project is the development of an upgraded Power module, redesigned for higher efficiency and adaptability. This major upgrade eliminates dependencies on external components, increases power output, and expands its application across multiple industries, from heavy manufacturing to AI DataCenters and hydrogen production.
The project aims to address the challenge of harvesting low-grade waste heat and converting it into clean, renewable electricity. By leveraging advanced heat recovery and power conversion technologies, ZIGRID is developing a highly scalable solution that enhances industrial energy efficiency while reducing carbon emissions.
Context and Overall Objectives
At the heart of the ZIGRID project is the development of an upgraded Power module, redesigned for higher efficiency and adaptability. This major upgrade eliminates dependencies on external components, increases power output, and expands its application across multiple industries, from heavy manufacturing to AI DataCenters and hydrogen production.
The project aims to address the challenge of harvesting low-grade waste heat and converting it into clean, renewable electricity. By leveraging advanced heat recovery and power conversion technologies, ZIGRID is developing a highly scalable solution that enhances industrial energy efficiency while reducing carbon emissions.
ZIGRID Project: Work Performed and Main Achievements
Introduction
A major achievement in the ZIGRID project has been the transition to a stand-alone power module, significantly improving efficiency, adaptability, and scalability. This redesign, which stemmed from subsystem optimization and certification requirements, has led to efficiency gains exceeding 50% and positioned ZIGRID for successful pilot implementation in AI DataCenters. The combination of iterative testing, real-world system validation, and supplier coordination has positioned ZIGRID ahead of schedule in key technical areas.
WP1: Subsystem Development and Optimization
• Power Module Redesign:
o The power module is upgraded enhancing efficiency, scalability, and simplifying certification.
o The redesigned module includes additional cylinders, leading to smoother and more continuous power production.
o Optimization of drivetrain and hydraulic components improved torque, RPM efficiency, and overall energy conversion.
• Subsystem Interfaces and Real-World Testing:
o While Digital Twin simulations have played a role in system refinement, real-world testing at facilities like BAETTR and the Jönköping Engine Lab provided critical insights that shaped the final design of the upgraded power module.
o Physical validation of cylinder performance and heat management led to major design improvements.
WP2: IoT Platform Implementation
• IoT Pre-Study and Standard Platform Selection:
o The pre-study led to the selection of a standard IoT platform, reducing development effort and accelerating deployment.
o Integration of sensors with PLCs ensures continuous, real-time data availability.
o Live IoT data streams from power modules now support real-time performance tracking and predictive maintenance.
WP3: System Demonstration and Certification
• Pilot Shift to liquid cooled DataCenters:
o Given the upgraded power module’s enhanced adaptability and efficiency with up to 50% higher energy conversion—the pilot will likely shift to an AI DataCenter.
o This strategic pivot is driven by delays in the Green Hydrogen roadmap across the EU and US, while AI DataCenters represent an immediate, high-growth market for ZIGRID’s technology.
o The ability to integrate waste heat recovery into liquid-cooled AI infrastructures positions ZIGRID as a key player in this rapidly expanding sector.
• Certification Progress:
o Collaboration with RISE progressed smoothly, with ongoing work on meeting EU directives and preparing certification documentation.
o Early supplier selection ensures that certified components align with quality and scalability requirements.
Introduction
A major achievement in the ZIGRID project has been the transition to a stand-alone power module, significantly improving efficiency, adaptability, and scalability. This redesign, which stemmed from subsystem optimization and certification requirements, has led to efficiency gains exceeding 50% and positioned ZIGRID for successful pilot implementation in AI DataCenters. The combination of iterative testing, real-world system validation, and supplier coordination has positioned ZIGRID ahead of schedule in key technical areas.
WP1: Subsystem Development and Optimization
• Power Module Redesign:
o The power module is upgraded enhancing efficiency, scalability, and simplifying certification.
o The redesigned module includes additional cylinders, leading to smoother and more continuous power production.
o Optimization of drivetrain and hydraulic components improved torque, RPM efficiency, and overall energy conversion.
• Subsystem Interfaces and Real-World Testing:
o While Digital Twin simulations have played a role in system refinement, real-world testing at facilities like BAETTR and the Jönköping Engine Lab provided critical insights that shaped the final design of the upgraded power module.
o Physical validation of cylinder performance and heat management led to major design improvements.
WP2: IoT Platform Implementation
• IoT Pre-Study and Standard Platform Selection:
o The pre-study led to the selection of a standard IoT platform, reducing development effort and accelerating deployment.
o Integration of sensors with PLCs ensures continuous, real-time data availability.
o Live IoT data streams from power modules now support real-time performance tracking and predictive maintenance.
WP3: System Demonstration and Certification
• Pilot Shift to liquid cooled DataCenters:
o Given the upgraded power module’s enhanced adaptability and efficiency with up to 50% higher energy conversion—the pilot will likely shift to an AI DataCenter.
o This strategic pivot is driven by delays in the Green Hydrogen roadmap across the EU and US, while AI DataCenters represent an immediate, high-growth market for ZIGRID’s technology.
o The ability to integrate waste heat recovery into liquid-cooled AI infrastructures positions ZIGRID as a key player in this rapidly expanding sector.
• Certification Progress:
o Collaboration with RISE progressed smoothly, with ongoing work on meeting EU directives and preparing certification documentation.
o Early supplier selection ensures that certified components align with quality and scalability requirements.
Results Beyond the State of the Art
The ZIGRID project has successfully advanced the state-of-the-art in low-temperature waste heat conversion, demonstrating net power production at only 40°C—a milestone that significantly expands the application potential of our technology. Unlike traditional waste heat recovery systems, which struggle with efficiency at lower temperatures, ZIGRID’s upgraded power module achieves a wider operational range. Our latest developments confirm that we have successfully extended the operating temperature span on the warm side from 90-60°C to 90-50°C, further improving energy extraction efficiency.
Key Impacts and Next Steps
1. Market Expansion Through Lower Temperature Operation
o These efficiency improvements allow ZIGRID’s technology to be implemented in a broader range of industrial processes, including AI DataCenters, process industries, and hydrogen production.
o The ability to function effectively at lower temperatures makes the system more attractive to industries where waste heat was previously too low to recover efficiently.
2. Demonstration and Commercialization Needs
o The next step is a full-scale demonstration at a Green Hydrogen production site or at a Liquid-Cooled DataCenter. The liquied cooled DataCenter has emerged as the most promising business case due to rapid industry growth and immediate waste heat utilization needs.
o Continued performance validation and system optimization will ensure readiness for full market deployment.
The ZIGRID project has successfully advanced the state-of-the-art in low-temperature waste heat conversion, demonstrating net power production at only 40°C—a milestone that significantly expands the application potential of our technology. Unlike traditional waste heat recovery systems, which struggle with efficiency at lower temperatures, ZIGRID’s upgraded power module achieves a wider operational range. Our latest developments confirm that we have successfully extended the operating temperature span on the warm side from 90-60°C to 90-50°C, further improving energy extraction efficiency.
Key Impacts and Next Steps
1. Market Expansion Through Lower Temperature Operation
o These efficiency improvements allow ZIGRID’s technology to be implemented in a broader range of industrial processes, including AI DataCenters, process industries, and hydrogen production.
o The ability to function effectively at lower temperatures makes the system more attractive to industries where waste heat was previously too low to recover efficiently.
2. Demonstration and Commercialization Needs
o The next step is a full-scale demonstration at a Green Hydrogen production site or at a Liquid-Cooled DataCenter. The liquied cooled DataCenter has emerged as the most promising business case due to rapid industry growth and immediate waste heat utilization needs.
o Continued performance validation and system optimization will ensure readiness for full market deployment.