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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 2 - TASIO (Waste Heat Recovery for Power Valorisation with Organic Rankine Cycle Technology in Energy Intensive Industries)

Teaser

Summary

The main objective of the project is to develop innovative solutions for the recovery and reuse of waste heat produced in Energy Intensive Industries (EII). The main result will be the design, setting up and validation of a new Organic Rankine Cycle (ORC) installation incorporating the direct heat exchange concept.

The ORC 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).

The consortium formed to carry out the project consists of 8 partners from 3 European countries. Four industrial participants representing cement, steel and glass sectors together with an ORC builder are collaborating with 2 technological centres and 2 engineering companies.

Work performed

Work performed and main results achieved in the first 30 months (December 2014- May 2017)

The report contains the summary of the work and results corresponding to the first 30 months of the project. The technical milestones have been achieved and not any technical deviation is foreseen. Following the main aspects approached in each of the workpackages is described.

WP1 Management and Coordination
The main issue related to coordination was the substitution of one of the original participants Holcim-Romania by the Italian company Cementi Giovanni Rossi due to the internal reorganization of the former following the merge of Holcim and Lafarge companies.

WP2 Evaluation of heat recovery potentials in EII.
This task has been finished on time. 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.

WP3 Development of a new generation of ORC turbogenerators
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.

WP4Advanced monitoring & control systems
The new WHRS concept may require different monitoring and control systems due to the new process conditions that the ORC equipment must withstand derived from the direct contact of hot (300-450ÂºC) and corrosive dusty flue gases coming from the flue gases of the EII processes. The work related to control and monitoring concluded in 2017.

WP5 Design and integration of the waste heat recovery system
During the last 12 months the simulation of the whole WHRS cycle performance has been done and subsequently the final design was finished.

WP6 Design and concept validation of the WHRS for air compressors Energy supply
During 2016 the transmission system was set up, the pilot ORC equipment was adapted and demonstration and validation of the concept at pilot plant scale trials were performed.

WP7 Validation and demonstration of the WHRS in Real Production conditions.
So far task 7.1 devoted to the design of the validation trials and adaptation of the existing industrial cement plant belonging to Cementi Rossi in Piacenza is finished and the work is now focused on task 7.2 dealing with the fabrication of the new ORC prototype with the DHE concept incorporated.

WP8 : Analysis of the replicability and adaptability of the developed technology to different sectors
The use of direct heat exchange ORC for electricity production has been analysed, as case study, for petrochemical sludge gasification. A model of the whole process has been realized and has been tuned with data arising from experimental campaign on CSM 50kg/h pilot plant. Subsequently the model has been scaled up in case of an industrial plant scale of 2000kg/h. Eventually the Cost-Volume-Profit analysis has shown that main factors, influencing the payback time, are: size of the plant, type of application, electric energy price and working hours.

WP9: Dissemination, exploitation and IPR strategies
During the last year the activities in dissemination and exploitation issues have got increased in agreement with the technical development of a preliminary exploitation strategy for the future implementation of the TASIO project outcomes has been developed and discussed. 4 main exploitable results have been identified. During the last months an intense activity aimed to disseminate TASIO project was made though the support of GEONARDO, in particular via Twitter.
The TASIO website (www.tasio-h2020.eu. ) has been continuously updated paying a special attention to the public section of the website. The number of public deliverables was increased during the process of the amendment request and a

Final results

The following aspects that are beyond the current state of the art have been developed so far:

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
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.
Testing of different Steel and coating combinations under real conditions in contact with flue gases produced in glassmaking, steelmaking and cement production processes. Testers with up to 12 different matrix/coating combinations have been located in the interior of chimneys the flue gases are vented to the atmosphere through. After 4-6 months the testers have been recovered and analysed to ascertain the performance of each of the materials in contact with hot flue gases

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 has been confirmed in the analysis and studies carried out so far in the project. 4 Key exploitable results ahve been identified and characterised and the first versiÃ³n of the exploitation plan hasa been drawn up.