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Upgrading of waste heat to process heat for different industries (From Waste Heat to Process Heat) - W2PHeat

01.01.2012 - 31.12.2013

 

GOAL: Showing the economical use of heat pumps in industrial environment is the overall goal of the project. A new technology (high temperature heat pump – HT HP) is to be developed, aiming at upgrading process heat by the use of unavoidable waste heat. Making this available it could be a key-technology to decrease the excess of waste heat into the environment and to reduce the energy demand for energy-intensive industries like pulp and paper, food, brick, chemical and textile.
BACKROUND: Often a lot of waste heat in industry is completely or partially dissipated into the environment while there is still need for process heat in the form of warm or hot water, low pressure steam or warm air etc. By using heat pumps, waste heat can be upgraded to a higher temperature level. Even though heat pumps are long known, they can be rarely found in industrial environment. The maximum output temperature of approximately 80 to 90°C and the unfavourable electricity/fuel price ration are predominant reasons for the lack of heat pump applications in industry.
INNOVATION TARGET: The development of the high temperature heat pump will be the main goal of this project, which includes the selection of suitable working fluids, the definition of a proper cycle architecture, the retrofitting of an existing compressor to make it compatible with high temperature operation, the optimization of heat exchangers and the elaboration of economical compressor driving technologies. Upgrading waste heat to process heat gives industry the opportunity to achieve higher process temperatures at constant or lower production costs. For the paper industry processes will be developed to create a suitable process environment for integrating the heat pump technology. The aim of that process development is to investigate the influence of higher process temperatures on process optimisation, product quality, and production costs.
In the frame of this project it is planned to develop a model installation which allows the using of straw as a basic raw material for the substantial and energetic utilization. In the process the motor cooling water (90°C) of a combined heat and power plants (CHP - Plants) is to be used alternatively for a straw decomposition process at a temperature of 140°C or for a double stage vacuum evaporator (110°C) to recover process water. METHODOLOGY: For the development of the heat pump and suitable processes following steps will be performed: literature research, on-site investigations, simulation works, laboratory tests, and demonstration with the help of test facilities.
EXPECTED RESULTS: The project will provide information about the feasibility to reverse the ORC process, achievable output temperatures of high temperature heat pump, economic and environmental aspects of industrial heat pump applications.

ECONOMIC IMPACT/POTENCIAL TO EXPLOIT R&D-RESULTS: Integrating waste heat into the process by using high temperature heat pump can reduce energy costs and make an important contribution to reduce greenhouse gases. Suppliers of heat pumps, heat exchanger, compressor and driving machines, like gas motors or gas turbines, plant engineers and designers can use the project results to cover new markets if the implementing of heat pumps will increase. Results will be transferred to the SMEs from three different European countries/regions in SME User Committees, by directly involving industrial partners from targeted sectors, by performing case studies, by website, organizing workshops and seminars.
PRE-COMPETETIVE CHARACTER: The results envisaged in this project, will not be specific for the tested factories but universally applicable, so that they can be used by all factories within the focused sectors and in sectors beyond. The results will be discussed within the SME User Committees and will be made public by wide ranged dissemination. PROJECT CONSORTIUM: The project will be performed by a consortium consisting of research centres and universities, covering complementary competences. Partners are experts in biogas and pulp and paper industry, experts in ORC and HVAC technologies, heat pump and compressor specialist. All partners are experienced in national and multinational project management.

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