Skip to main content

Sustainable Production of Industrial Recovered Energy using energy dissipative and storage technologies

Periodic Reporting for period 1 - SUSPIRE (Sustainable Production of Industrial Recovered Energy using energy dissipative and storage technologies)

Reporting period: 2015-10-01 to 2017-03-31

Energy in energy intensive industries is used to transform the chemical composition or the shape of raw materials or starting components. A very small quantity of this energy will remain integrated in the material itself. Supplied energy is lost in aspect such as radiation , intermediate or finished products remaining heat that are cooled to the open air or in residual heat streams. This energy looses are estimated in around 20 to 50% of the total consumption in one production plant. This project will focus on residual heat streams that can be classified by their physical condition: liquid, solid or gas and by the temperature range that they have. This project has identified investment casting manufacturing process with its corresponding residual heat streams as representative of a significant number of energy intensive industries such as steel, glass, cement, food industry. Identified residual heat streams are basically:
• High temperature exhaust gases from combustion furnaces that are generated in a continuous way. Exhaust gases get out from the furnace at around 800ºC.
• Steam getting out of the boilerclave at around 100ºC and that is discontinuously generated.
• Cooling water from different equipments such as: Wax injection units, compressors, induction furnaces.

Different technical solutions have been identified in this project to accomplish the efficient energy recovery of this residual heat streams that should result as SUSPIRE final goal in a 20% reduction in the energy consumption of the plant..
By one side technical development will be carried out in the way of achieving higher levels of energy recovery that include:
• Development of PCM based heat exchanger for high temperature exhaust gases..
• Development of PCM based heat exchanger for steam release in boilerclave.
• High efficiency Heat transfer Fluids (HTF) for high temperature efficient energy recovery.
• A high temperature energy buffer will be develop to distribute energy to plant consumption point or to a BTES (Borehole Thermal Energy Storage System (BTES)) that will accumulate low temperature energy and use the heat pump to supply heat or cool for buildings acclimatization.
• The energy recovery process will be controlled by a smart data management system that will achieve the best energy recovery yield maintaining or improving the manufacturing and quality ratios

These technical developments will be carried out by developing different activities, distributed among the partners that conforms the project consortium:
1. Project management to coordinate the actions and the development of the project between the different partners and the European commission.
2. Preliminary study of actual existing technologies of energy recovery as well as constructive materials, Phase Change Materials (PCMs) and Heat Transfer Fluids (HTF). Market potential analysis based on extrapolation on other energy intensive industries.
3. Recovery system lay-out and energy management system definition for later on implementation of the system in the plant.
4. Equipment design in terms of construction materials: liquids for heat transport and materials for heat exchange and accumulation, including Phase Change Materials (PCMs).
5. Pilot development for setting up of developed technologies and energy management methodologies.
6. Develop a system complete and qualified once the setting up has finished and should be proven in real manufacturing conditions.
7. Dissemination and exploitation of data for fast uptake of the developed technologies by the European market.
During this working period corresponding to the first 18 months the following activities have been carried out: WP2, WP3 and WP4 and final results from performed activities have carried out as main results:

- A new heat exchanger design for a boilerclave exhaust steam energy recovery, incorporating a PCM with graphite addition that achieves a significant yield of energy recovery for retrofiiing of energy to the same system.
- A heat exchanger with a design that allow achieving a significat energy recovery from exhaust gases of a chimeny at 800ºCsupported in an exteranl buffer that uses an inorganic PCM for later on use in plant or be sold to third parties.
- A new designed of Bore hole thermal energy storage system that works in cascade with the high temperature energy recovery of gases to accumulate excess of not consumed energy for seasonal use in the ground.
- A data management system that deals with manufacturing data of rejection rates and energy recovery yield to obtain the best balance between both systems.

The dissemination has taken place over different congresses adn fairs StatusPrediction of lifetime of critical components for energy efficient installations /Tribology International/Lubmat (C) 2016/International Conference “Environmental Engineering”, Vilnius, 28 April 2017/ Geoner 2017 V Congreso de energía geotérmica aplicado a la edificación y a la industria , Madrid, 26 Abril 2017.
Actual plants have several handicaps to integrate this type of systems as in their lay out energy recovery of industrial heat streams has not been an objective. This project aims to be a reference to systematically integrate the products, equipments and smart control systems that will be developed in an industrial plant with intensive energy consumption. A future challenge could be to apply the technology and methodology developed as part of the manufacturing process.
Heat exchangers with a high accumulation capacity rate can be extrapolated to other segment niches as exhaust gases in the transport area where energy can be stored and further used in for fuel preheating or transferred for external applications.
Industry with less intensive energy consumption, but with local generation of this residual heat streams, can also take advantage of these new technologies due to be more affordable by their development in the market. The PCM resulting from this project will open the window for new business by formulating and commercializing these products.
Smart systems based on the factory 4.0 philosophies could be used for further automatic interaction with machines arriving to a complete energy recovery Cyberphysical system. This monitoring and control of energy consumption included for its use in houses and flats acting directly over energy consumption at any moment or suggesting best practises of energy use.
Scheme of energy recovery system