Industrial Thermal Energy Recovery, Conversion ... - sCO2-flex

Industrial Thermal Energy Recovery Conversion and Management

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 680599.

Industrial Thermal Energy Recovery, Conversion and Management

‘I-ThERM’

Savvas A Tassou & Matteo Marchionni

Project Number: 680599

Pilot Implementation Challenge and Lessons Learned


European Union’s Horizon 2020 research and innovation programmegrant agreement No 680599

Brunel University LondonInstitute of Energy Futures

Medium size university (15000 students) - outskirts of London

2500 staff (700 academic)

Turnover ~270 million EUR of which around 30 million EUR in research income

annually.

Current H2020 projects by the Brunel Research Team

I-ThERM – Industrial Thermal Energy Recovery and Management,

2015 -2021 – Coordinators – GA 680599

ASTEP - Application of Solar Thermal Energy to Processes (2020-2024) - GA

884411.

CO2OLHEAT Supercritical CO2 power cycles demonstration in Operational

environment Locally valorising industrial Waste Heat (2021 – 2025).


European Union’s Horizon 2020 research and innovation programmegrant agreement No 680599 3

Aim of the I-ThERM Project

Investigate, design, build and demonstrate innovative plug and play waste heat recovery solutions to facilitate optimum utilisation of energy in

selected industrial applications with high replicability and energy recovery potential in the temperature range 70oC-1000oC.



Major Objectives:Develop heat recovery and heat to power conversion technologies in packaged

or easily customisable plug and play forms that can readily be applied in industry.

Develop an intelligent system for monitoring and on-line integration and control of the operation of these technologies to maximise heat recovery and conversion.

Implement, monitor and evaluate the performance of the technologies, evaluate their impact on overall energy consumption and CO2 emissions.

Disseminate the outputs widely to industry, other key stakeholders and policy makers.



CONSORTIUM13 partners: 3 large industry, 7 SMEs, 3 RTDs



4 PLUG AND PLAY TECHNOLOGIES

Flat Heat Pipe System

Heat Pipe CondensingEconomiser

Trilateral Flash Cycle (TFC)

Supercritical CO2(sCO2) cycle


European Union’s Horizon 2020 research and innovation programmegrant agreement No 680599 7BUL

Trilateral Flash Cycle System (TFC)

Objective:Develop build and demonstrate a TFC system suitable for waste heat to power conversion at less than 100oC.


European Union’s Horizon 2020 research and innovation programmegrant agreement No 680599 8BUL

Supercritical CO2 (sCO2) Heat to Power System Demonstrator

Objective:Develop build and demonstrate a 50 kWe sCO2 system suitable for waste

heat to power conversion at temperatures up to 800 oC.

Demonstration site:

Brunel University London.

Heat rejection from gas fired heat source.

Research and Development work:

i) Simulate, design and build a 50 kWe unit;

ii) Design and procure a 1.0 MW heat source;

iii) Design and build test facilities;

iv) Commission, test and demonstrate the unit.



50 kWe design power output at ~20%

efficiency

Simple regenerative layout

Developed through multi-scale (0D-1D-3D)

modelling and control

min/max pressure [bar]

min/max Temperature [°C]

CO2 mass flow rate [kg/s]

75/127.5 35/400 2.25

sCO2 Heat to Power System Demonstrator



sCO2 Heat to Power System Demonstrator

800 kWth heat source (Process Air Heater)

Simple regenerative layout

Developed through multi-scale (0D-1D-3D)

modelling and control



Supercritical CO2 (sCO2) heat to power Cycle

Power generation unit

Gas cooler Plate heat exchanger

Heatric 600kW recuperatorPrinted circuit heat exchanger



Heat exchanger design

Heat Exchangers



3D CFD Modelling

PCHE



Monitoring, Control and Communications System

High Temperature Test Section

up to 2m

combustion air fan

cooling air fan

Low temperature test section

stack

1 kg/s at 780°C and 70mbarg

flowMicro-tube heater

Water-glycolmixture

Heat sink controller

Centralised Monitoring and control

platform

sCO2 data acquisition system and supervisory controller

Heat source controller

CGT controller

sCO2heat to power conversion unit

Modbus

Online monitoring

Demonstrator control architecture (IEC 61499 standard)

Online platform



Dynamic Simulation

0 30 60 90 120 150time [s]

0.00

0.50

1.00

1.50

2.00

2.50

mas

s flo

w ra

te [k

g/s]

30

45

60

255

270

285

300

inle

t tem

pera

ture

[o C]

74

80

86

92

98

inle

t pre

ssur

e[ba

r]

Hot side Cold side

(a)

0 30 60 90 120 150time [s]

0.80

0.85

0.90

0.95

1.00

effe

ctive

ness

0

100

200

300

400

500

600

700

ther

mal

pow

er [k

W]

0.00

0.50

1.00

1.50

2.00

pres

sure

dro

p [b

ar]

(c)

1D modelling approach Performance maps

Transient simulations

Research methodology

Pros:• Low computational cost• Transient analysis & control• Component & systems simulations



Dynamic Simulation

0 400 800 1200 1600 2000 2400 2800time [s]

650

725

800

875

950

Turb

ine

inle

t tem

pera

ture

[K]

Turbomachinery revolution speedTBV fully open / CBV fully closed

TBV fully open / CBV fully openTBV fully closed / CBV fully closed

0

2x104

3x104

5x104

6x104

8x104

9x104

Rev

olut

ion

spee

d [R

PM]

Turbine performance mapTBV fully open/CBV full closedTBV fully closed/ CBV fully closedTBV fully open/CBV fully open

Start-up and shut-down

0 400 800 1200 1600 2000 2400 2800time [s]

0.70.91.11.3

2.2

2.3

mas

s flo

w ra

te [k

g/s]

707274

130

135

140

145

pres

sure

[bar

]

312314316600800

1000

1200

tem

pera

ture

[K]

Flue gasCompressor inlet

Turbine inletCO2

Net powerEfficiency

0.1

0.2

0.340

60

80

effic

ienc

y / p

ower

[kW

]

1D CFD system model



0 200 400 600 800 1000 1200 1400time [s]

0

0.1

0.2

45

60

75

90

Effi

cien

cy /

Net

pow

er [k

W]

700

800

900

1000

Tem

pera

ture

[K]

WHS temperatureSet point

Uncontrolled responseControlled response

• Inventory control• Heat load following control

strategy• Turbine inlet temperature

as control objective

Control strategy simulationsComparison of control variables

(Inventory vs Turbomachine speed)



Inventory Control

Inventory tanks finite capacity

75 85 95 105 115Tank initial pressure [bar]

250

300

350

400

450

500

550

600

650

Turb

ine

inle

t tem

pera

ture

[o C]

Inventory tank volume (percentage of loop volume)30% 100% 300%

CO2 withdrawal

CO2 injection

Inventory tank sizing and dynamics

75 85 95 105 115Tank initial pressure [bar]

70

80

90

100

110

120

130

140

Equi

libriu

m p

ress

ure

[bar

]

Inventory tank volume (percentage of loop volume)30% 100% 300%

CO2 withdrawal

CO2 injection



Commission turbomachinery and complete unit

Validate steady state and dynamic simulation models

Utilise test facility for:

Advanced heat exchanger development and testing

Investigation of control strategies

Different cycle and turbomachinery arrangements

Future Developments



Questions?

Thank You

Industrial Thermal Energy Recovery, Conversion ... - sCO2-flex

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