Low-grade heat conversion into power using organic Rankine cycles – A review of various applications

An organic Rankine cycle (ORC) machine is similar to a conventional steam cycle energy conversion system, but uses an organic fluid such as refrigerants and hydrocarbons instead of water. In recent years, research was intensified on this device as it is being progressively adopted as premier technology to convert low-temperature heat resources into power. Available heat resources are: solar energy, geothermal energy, biomass products, surface seawater, and waste heat from various thermal processes. This paper presents existing applications and analyzes their maturity. Binary geothermal and binary biomass CHP are already mature. Provided the interest to recover waste heat rejected by thermal devices and industrial processes continue to grow, and favorable legislative conditions are adopted, waste heat recovery organic Rankine cycle systems in the near future will experience a rapid growth. Solar modular power plants are being intensely investigated at smaller scale for cogeneration applications in buildings but larger plants are also expected in tropical or Sahel regions with constant and low solar radiation intensity. OTEC power plants operating mainly on offshore installations at very low temperature have been advertised as total resource systems and interest on this technology is growing in large isolated islands.     

Decentralised optimisation of cogeneration in virtual power plants

Within several projects we investigated grid structures and management strategies for active grids with high penetration of renewable energy resources and distributed generation (RES & DG). Those ”smart grids” should be designed and managed by model based methods, which are elaborated within these projects. Cogeneration plants (CHP) can reduce the greenhouse gas emissions by locally producing heat and electricity. The integration of thermal storage devices is suitable to get more flexibility for the cogeneration operation. If several power plants are bound to centrally managed clusters, it is called “virtual power plant”. To operate smart grids optimally, new optimisation and model reduction techniques are necessary to get rid with the complexity.There is a great potential for the optimised management of CHPs, which is not yet used. Due to the fact that electrical and thermal demands do not occur simultaneously, a thermally driven CHP cannot supply electrical peak loads when needed. With the usage of thermal storage systems it is possible to decouple electric and thermal production. We developed an optimisation method based on mixed integer linear programming (MILP) for the management of local heat supply systems with CHPs, heating boilers and thermal storages. The algorithm allows the production of thermal and electric energy with a maximal benefit. In addition to fuel and maintenance costs it is assumed that the produced electricity of the CHP is sold at dynamic prices. This developed optimisation algorithm was used for an existing local heat system with 5 CHP units of the same type. An analysis of the potential showed that about 10% increase in benefit is possible compared to a typical thermally driven CHP system under current German boundary conditions. The quality of the optimisation result depends on an accurate prognosis of the thermal load which is realised with an empiric formula fitted with measured data by a multiple regression method.The key functionality of a virtual power plant is to increase the value of the produced power by clustering different plants. The first step of the optimisation concerns the local operation of the individual power generator, the second step is to calculate the contribution to the virtual power plant. With small extensions the suggested MILP algorithm can be used for an overall EEX (European Energy Exchange) optimised management of clustered CHP systems in form of the virtual power plant. This algorithm has been used to control cogeneration plants within a distribution grid.     

Application of combined heat-and-power and absorption cooling in a supermarket

In recent years, it has become standard practice to consider Combined Heat-and-Power (CHP) systems for commercial buildings. CHP schemes are used, because they are an efficient means of power generation. Unlike conventional power stations, they produce electricity locally and thus minimise the distribution losses, however, they also utilise the waste heat from the generation process. In applications where there is a combined heating and electricity requirement, a very efficient means of energy production is achieved compared to the conventional methods of providing heating and electricity. With new initiatives from the UK government on reduced energy-use, energy-efficient systems such as CHP have been considered for new applications. This paper summarises the results of an investigation into the viability of CHP systems in supermarkets. The viability of conventional CHP has been theoretically investigated using a mathematical model of a typical supermarket. This has demonstrated that a conventional CHP system may be practically applied. It has also been shown that compared to the traditional supermarket design, the proposed CHP system will use slightly less primary energy and the running costs will be significantly reduced. An attractive payback period of approximately 4 years has been calculated. Despite these advantages a considerable quantity of heat is rejected to atmosphere with this system and this is because the configuration utilises the heat mainly for space heating which is only required for part of the year. To increase the utilisation time, a novel CHP/absorption system has been investigated. This configuration provides a continuous demand for the waste heat, which is used to drive an absorption chiller that refrigerates propylene glycol to −10°C for cooling the chilled-food cabinets. The results show this concept to be theoretically practical. The system has also been shown to be extremely efficient, with primary energy savings of approximately 20%, when compared to traditional supermarket designs and this would result in significant revenue cost savings as well as environmental benefits. Based upon these savings a payback period for this system of approximately 5 years has been demonstrated.     

Energetic and exergetic analysis of steam production for the extraction of coniferous essential oils

Bioenergy production is optimal when the energy production process is both efficient and benefits from local resources. Energetic and exergetic analyses are applied to highlight efficiency differences between small-size systems that are based on the co-generation of heating and power (CHP) versus the co-generation of heating and power with steam production (CHP-S). Both systems use the Organic fluid Rankine Cycle (ORC).The recovery of heat from flue gases is considered to be a way of increasing energy efficiency. In the CHP-S case, steam (at low pressure) is used to extract essential oils from fresh twigs and needles of coniferous trees throughout a steam distillation process. When the systems work at a thermal combustion power of 1350 kW, energetic analysis shows that the energy efficiency of the CHP-S plant (89.4%) is higher than that of the CHP plant (77.9%). Exergetic analysis shows that the efficiency of the CHP-S plant is 2.2% higher than that of the CHP plant.     

Value of electric heat boilers and heat pumps for wind power integration

The paper analyses the economic value of using electric heat boilers and heat pumps as wind power integration measures relieving the link between the heat and power production in combined heat and power plants. Both measures have different technical and economic characteristics, making a comparison of the value of these measures relevant. A stochastic, fundamental bottom‐up model, taking the stochastic nature of wind power production explicitly into account when making dispatch decisions, is used to analyse the technical and economical performance of these measures in a North European power system covering Denmark, Finland, Germany, Norway and Sweden. Introduction of heat pumps or electric boilers is beneficial for the integration of wind power, because the curtailment of wind power production is reduced, the price of regulating power is reduced and the number of hours with very low power prices is reduced, making the wind power production more valuable. The system benefits of heat pumps and electric boilers are connected to replacing heat production on fuel oil heat boilers and combined heat and power (CHP) plants using various fuels with heat production using electricity and thereby saving fuel. The benefits of the measures depend highly on the underlying structure of heat production. The integration measures are economical, especially in systems where the marginal heat production costs before the introduction of the heat measures are high, e.g. heat production on heat boilers using fuel oil. Copyright © 2007 John Wiley & Sons, Ltd.     

Experimental investigation of a novel heat pipe thermoelectric generator for waste heat recovery and electricity generation

Waste heat recovery helps reduce energy consumption, decreases carbon emissions, and enhances sustainable energy development. In China, energy-intensive industries dominate the industrial sector and have significant potential for waste heat recovery. We propose a novel waste heat recovery system assisted by a heat pipe and thermoelectric generator (TEG) namely, heat pipe TEG (HPTEG)，to simultaneously recover waste heat and achieve electricity generation. Moreover, the HPTEG provides a good approach to bridging the mismatch between energy supply and demand. Based on the technical reserve on high-temperature heat pipe manufacturing and TEG device integration, a laboratory-scale HPTEG prototype was established to investigate the coupling performances of the heat pipes and TEGs. Static energy conversion and passive thermal transport were achieved with the assistance of skutterudite TEGs and potassium heat pipes. Based on the HPTEG prototype, the heat transfer and the thermoelectric conversion performances were investigated. Potassium heat pipes exhibited excellent heat transfer performance with 95% thermal efficiency. The isothermality of such a heat pipe was excellent, and the heat pipe temperature gradient was within 15°C. The TEG's thermoelectric conversion efficiency of 7.5% and HPTEG's prototype system thermoelectric conversion efficiency of 6.2% were achieved. When the TEG hot surface temperature reached 625°C, the maximum electrical output power of the TEG peaked at 183.2 W, and the open-circuit voltage reached 42.2 V. The high performances of the HPTEG prototype demonstrated the potential of the HPTEG for use in engineering applications.     

Comparative analyses of seven technologies to facilitate the integration of fluctuating renewable energy sources

An analysis of seven different technologies is presented. The technologies integrate fluctuating renewable energy sources (RES) such as wind power production into the electricity supply, and the Danish energy system is used as a case. Comprehensive hour-by-hour energy system analyses are conducted of a complete system meeting electricity, heat and transport demands, and including RES, power plants, and combined heat and power production (CHP) for district heating and transport technologies. In conclusion, the most fuel-efficient and least-cost technologies are identified through energy system and feasibility analyses. Large-scale heat pumps prove to be especially promising as they efficiently reduce the production of excess electricity. Flexible electricity demand and electric boilers are low-cost solutions, but their improvement of fuel efficiency is rather limited. Battery electric vehicles constitute the most promising transport integration technology compared with hydrogen fuel cell vehicles (HFCVs). The costs of integrating RES with electrolysers for HFCVs, CHP and micro fuel cell CHP are reduced significantly with more than 50% of RES.     

Design,testing and mathematical modelling of a small-scale CHP and cooling system (small CHP-ejector trigeneration)

Trigeneration is the production of heat, cooling and power from one system. It can improve the financial and environmental benefits of combined heat and power (CHP) by using the heat output from the CHP unit to drive a cooling cycle, as demonstrated in existing large-scale installations. However, small-scale systems of a few kW_e output present technological challenges. This paper presents the design and analysis of possible trigeneration systems based on a gas engine mini-CHP unit (5.5 kW_e) and an ejector cooling cycle. Analysis shows that an overall efficiency around 50% could be achieved with systems designed for applications with simultaneous requirements for heat and cool. While using part of the CHP electrical output into the cooling cycle boosts the cooling capacity, it does not improve the overall efficiency and increases the CO₂ emissions of the system. Emissions savings compared to traditional systems could be achieved with improvements of the heat transfer from CHP to cooling cycle.     

Optimisation of merged district-heating systems—benefits of co-operation in the light of externality costs

Studies have shown that separate actors can benefit from co-operation around heat supply. Such co-operation, for example, might be between an industry selling waste heat to a district-heating system or two district-heating systems interconnecting their respective systems. Co-operation could also be expected to reduce the environmental impacts of the energy systems by choosing the plants with the lowest emissions. It is widely accepted that the production of heat and electricity causes damage to the environment. This damage often imposes a cost on society, but not on company responsible. In general, using a broader system perspective when analysing local energy systems results in a lower total cost, more efficient use of plants and a greater potential for producing electricity in combined heat-and-power (CHP) plants. Internalising the externality costs in the energy system model facilitates the study of what co-operation can mean for reducing emissions. This study shows that co-operation between the two systems is on the whole cost-effective, but the benefits are greater when external costs are not included in the calculation. Considering externality costs in combination with current electricity prices would lead to a higher system cost, but the quantity of emission gases will be lower. If, on the other hand, the calculation is made taking externality costs and corresponding adjusted electricity prices (the adjustment being necessary to compensate for the additional cost due to externality costs) into consideration, the quantities of emission gases will rise because more heat-and-power will be generated by one of the CHP plants.     

Dynamic modeling and evaluation of solid oxide fuel cell - combined heat and power system operating strategies

Operating strategies of solid oxide fuel cell (SOFC) combined heat and power (CHP) systems are developed and evaluated from a utility, and end-user perspective using a fully integrated SOFC-CHP system dynamic model that resolves the physical states, thermal integration and overall efficiency of the system. The model can be modified for any SOFC-CHP system, but the present analysis is applied to a hotel in southern California based on measured electric and heating loads. Analysis indicates that combined heat and power systems can be operated to benefit both the end-users and the utility, providing more efficient electric generation as well as grid ancillary services, namely dispatchable urban power.Design and operating strategies considered in the paper include optimal sizing of the fuel cell, thermal energy storage to dispatch heat, and operating the fuel cell to provide flexible grid power. Analysis results indicate that with a 13.1% average increase in price-of-electricity (POE), the system can provide the grid with a 50% operating range of dispatchable urban power at an overall thermal efficiency of 80%. This grid-support operating mode increases the operational flexibility of the SOFC-CHP system, which may make the technology an important utility asset for accommodating the increased penetration of intermittent renewable power.     

Energetic and economic investigation of Organic Rankine Cycle applications

The use of organic working fluids for the realization of the so called Organic Rankine Cycle (ORC) has been proven to be a promising solution for decentralized combined heat and power production (CHP). The process allows the use of low temperature heat sources, offering an advantageous efficiency in small-scale applications. This is the reason why the number of geothermal and biomass fired power plants based on this technology have been increased within the last years. The favourable characteristics of ORC make them suitable for being integrated in applications like solar desalination with reverse osmosis system, waste heat recovery from biogas digestion plants or micro-CHP systems. In this paper, the state of the art of ORC applications will be presented together with innovative systems which have been simulated in a process simulation environment using experimental data. The results of the simulation like efficiencies, water production rates or achievable electricity production cost will be presented and discussed.     

Evaluation of a low temperature fuel cell system for residential CHP

CHP (combined heat and power) is a technology that allows to provide electrical and thermal energy. CHP is normally used in systems that produce wasted heat at high temperature to recover energy and increase overall system efficiency. The aim of this work is to investigate the possibility to recover heat produced by a 5 kW PEFC system for residential applications (hot water and building heating). As known, PEFCs work at low temperature (60-90 °C) and the experiments have been carried out in order to improve the overall system efficiency by reusing heat that is normally wasted.The work was developed during an Italian National project PNR-FISR “Polymeric and Ceramic Fuel Cell” coordinated by CNR-ITAE. A 5 kW PEFC system, developed with NUVERA Fuel Cells in the framework of the project, was tested in cogeneration configuration recovering wasted heat with a heat exchanger directly connected to cathode out.Tests on PEFC system were carried out in the range 2.5-5 kW, maintaining the working stack temperature at 71 °C. Heat, produced at different power levels, was removed from the system by using a regulated water flow in the heat exchanger. A peculiar feature of the system is the so-called “direct water injection” at the cathode, that allows simultaneous cooling and humidification of the stack. This characteristic permitted the recovery of most of the waste heat produced by the fuel cell.The performance of the PEFC unit was analyzed in terms of electrical, thermal and total efficiency. Tests showed that it is possible to obtain water at about 68 °C under different power levels. Moreover, experimental data showed that heat recovered was maximum when heat exchanger worked at nominal power and, under these conditions, the overall system efficiency increased up to 85%.     

Cogeneration plant in an olive sludge industry

Spain is the world’s main producer of olive oil, with an annual production approaching 1 million tons. A great amount of wet residues are generated – mainly sludge, thus favouring the development of energy plants for their treatment and/or elimination. Such installations require a simultaneous electric and thermal energy demand, and combined heat and power (CHP) systems might be the most adequate in certain cases. The economic viability of a CHP system in a sludge processing plant (sludge obtained from olive oil extraction industry) is analysed in the present work. Special attention is paid to the analysis and discussion of energy savings and environmental benefits.     

Integrated energy systems and local energy markets

Significant benefits are connected with an increase in the flexibility of the Danish energy system. On the one hand, it is possible to benefit from trading electricity with neighbouring countries, and on the other, Denmark will be able to make better use of wind power and other types of renewable energy in the future. This paper presents the analysis of different ways of increasing flexibility in the Danish energy system by the use of local regulation mechanisms. This strategy is compared with the opposite extreme, i.e. trying to solve all balancing problems via electricity trade on the international market. The conclusion is that it is feasible for the Danish society to include the CHP plants in the balancing of fluctuating wind power. There are major advantages in equipping small CHP plants as well as the large CHP plants with heat pumps. By doing so, it will be possible to increase the share of wind power from the present 20 to 40% without causing significant problems of imbalance between electricity consumption and production. Investment in increased flexibility is in itself profitable. Furthermore, the feasibility of wind power is improved.     

Techno-economic evaluation of medium scale power to hydrogen to combined heat and power generation systems

The European Hydrogen Strategy and the new « Fit for 55 » package indicate the urgent need for the alignment of policy with the European Green Deal and European Union (EU) climate law for the decarbonization of the energy system and the use of hydrogen towards 2030 and 2050. The increasing carbon prices in EU Emission Trading System (ETS) as well as the lack of dispatchable thermal power generation as part of the Coal exit are expected to enhance the role of Combined Heat and Power (CHP) in the future energy system. In the present work, the use of renewable hydrogen for the decarbonization of CHP plants is investigated for various fossil fuel substitution ratios and the impact of the overall efficiency, the reduction of direct emissions and the carbon footprint of heat and power generation are reported. The analysis provides insights on efficient and decarbonized cogeneration linking the power with the heat sector via renewable hydrogen production and use. The levelized cost of hydrogen production as well as the levelized cost of electricity in the power to hydrogen to combined heat and power system are analyzed for various natural gas substitution scenarios as well as current and future projections of EU ETS carbon prices.     

Performance characterization of gas engine generator integrated with a liquid desiccant dehumidification system

Combined heat and power (CHP) involves on-site or near-site generation of electricity along with utilization of thermal energy available from the power generation process. CHP has the potential of providing a 30% improvement over conventional power plant efficiency and a CO₂ emissions reduction of 45% or more as compared to the US national average. In addition, an overall total system efficiency of 80% can be achieved because of the utilization of thermal energy that would be wasted if only the electric power were utilized, and because of the reduction of transmission, distribution, and energy conversion losses. The current research is being carried out in a four-story educational office building. This research focuses on the design, installation, and analysis of a modular CHP system consisting of a natural gas fired reciprocating engine generator with a liquid desiccant dehumidification system. The engine generator provides 75 kW of electric power to the building load bus while the combined waste heat from the exhaust gases and jacket water are used to regenerate the liquid desiccant. The liquid desiccant unit dehumidifies and cools the ventilation air to the building and supplies it to the mixed air section of the roof top unit. This paper discusses the various aspects involved in the design and installation of the system such as the heat recovery loop design and the electrical interconnection with the building load bus. Test results are also presented and the performance is compared to a traditional power plant with a conventional heating, ventilating, and air-conditioning system.     

Effect of Convection Heat Transfer on Performance of Waste Heat Thermoelectric Generator

Efficiency of energy conversion processes can be improved if waste heat is converted to electricity. A thermoelectric generator (TEG) can directly convert waste heat to electricity. The TEG typically suffers from low efficiency due to various reasons, such as ohmic heating, surface-to-surrounding convection losses, and unfavorable material properties. In this work, the effect of surface-to-surrounding convection heat transfer losses on the performance of TEG is studied analytically and numerically. A one-dimensional (1-D) analytical model is developed that includes surface convection, conduction, ohmic heating, and Peltier, Seebeck, and Thomson effects with top and bottom surfaces of TEG exposed to convective boundary conditions. Using the analytical solutions, different performance parameters (e.g., heat input, power output, and efficiency) are calculated and expressed graphically as functions of thermal source and sink temperatures and convection heat transfer coefficient. Finally, a two-dimensional (2-D) mathematical model is solved numerically to observe qualitative results of thermal and electric fields inside the TEG. For all calculations, temperature-dependent thermal/electric properties are considered. Increase in thermal source temperature results in an increase in the power output with adiabatic side wall conditions. A change in boundary condition to convection heat transfer from adiabatic boundary has a large impact on thermal efficiency.     

Upgrading waste heat from a cement plant for thermochemical hydrogen production

A calcium oxide/steam chemical heat pump (CHP) is presented in the study as a means to upgrade waste heat from industrial processes for thermochemical hydrogen production. The CHP is used to upgrade waste heat for the decomposition of copper oxychloride (CuO.CuCl₂) in a copper–chlorine (Cu–Cl) thermochemical cycle. A formulation is presented for high temperature steam electrolysis and thermochemical splitting of water using waste heat of a cement plant. Numerical models are presented for verifying the availability of energy for potential waste heat upgrading in cement plants. The optimal hydration and decomposition temperatures for the calcium oxide/steam reversible reaction of 485 K and 565 K respectively are obtained for the combined heat pump and thermochemical cycle. The coefficient of performance and overall efficiency of 4.6 and 47.8% respectively are presented and discussed for the CHP and hydrogen production from the cement plant.     

Experiments and simulations on low-temperature waste heat harvesting system by thermoelectric power generators

In this case study, a system to recover waste heat comprised 24 thermoelectric generators (TEG) to convert heat from the exhaust pipe of an automobile to electrical energy has been constructed. Simulations and experiments for the thermoelectric module in this system are undertaken to assess the feasibility of these applications. A slopping block is designed on the basis of simulation results to uniform the interior thermal field that improves the performance of TEG modules. Besides simulations, the system is designed and assembled. Measurements followed the connection of the system to the middle of an exhaust pipe. Open circuit voltage and maximum power output of the system are characterized as a function of temperature difference. Through these simulations and experiments, the power generated with a commercial TEG module is presented. Overview this case study and our previous work, the results establish the fundamental development of low-temperature waste heat thermoelectric generator system that enhances the TEG efficiency for vehicles.     

Large-scale integration of wind power into different energy systems

The paper presents the ability of different energy systems and regulation strategies to integrate wind power. The ability is expressed by the following three factors: the degree of electricity excess production caused by fluctuations in wind and Combined Heat and Power (CHP) heat demands, the ability to utilise wind power to reduce CO₂ emission in the system, and the ability to benefit from exchange of electricity on the market. Energy systems and regulation strategies are analysed in the range of a wind power input from 0 to 100% of the electricity demand. Based on the Danish energy system, in which 50% of the electricity demand is produced in CHP, a number of future energy systems with CO₂ reduction potentials are analysed, i.e. systems with more CHP, systems using electricity for transportation (battery or hydrogen vehicles) and systems with fuel-cell technologies. For the present and such potential future energy systems different regulation strategies have been analysed, i.e. the inclusion of small CHP plants into the regulation task of electricity balancing and ancillary grid stability services and investments in electric heating, heat pumps and heat storage capacity. The results of the analyses make it possible to compare short-term and long-term potentials of different strategies of large-scale integration of wind power.