Heat losses and thermal performance of commercial combined solar and pellet heating systems

Various pellet heating systems are marketed in Sweden, some of them in combination with a solar heating system. Several types of pellet heating units are available and can be used for a combined system. This article compares four typical combined solar and pellet heating systems: System 1 and 2 two with a pellet stove, system 3 with a store integrated pellet burner and system 4 with a pellet boiler. The lower efficiency of pellet heaters compared to oil or gas heaters increases the primary energy demand. Consequently heat losses of the various systems have been studied. The systems have been modeled in TRNSYS and simulated with parameters identified from measurements. For almost all systems the flue gas losses are the main heat losses except for system 3 where store heat losses prevail. Relevant are also the heat losses of the burner and the boiler to the ambient. Significant leakage losses are noticed for system 3 and 4. For buildings with an open internal design system 1 is the most efficient solution. Other buildings should preferably apply system 3. The right choice of the system depends also on whether the heater is placed inside or outside of the heated are. A large potential for system optimization exist for all studied systems, which when applied could alter the relative merits of the different system types.

Heat losses in a CVD reactor for polysilicon: comprehensive model and experimental validation

This work addresses heat losses in a CVD reactor for polysilicon production. Contributions to the energy consumption of the so-called Siemens process are evaluated, and a comprehensive model for heat loss is presented. A previously-developed model for radiative heat loss is combined with conductive heat loss theory and a new model for convective heat loss. Theoretical calculations are developed and theoretical energy consumption of the polysilicon deposition process is obtained. The model is validated by comparison with experimental results obtained using a laboratory-scale CVD reactor. Finally, the model is used to calculate heat consumption in a 36-rod industrial reactor; the energy consumption due to convective heat loss per kilogram of polysilicon produced is calculated to be 22-30 kWh/kg along a deposition process.

Numerical and experimental analysis of natural convection in a cavity with flush mounted heat sources on a side wall

This work considers a problem of interest in several technological applications such as the thermal control of electronic equipment. It is also important to study the heat transfer performance of these components under off-normal conditions, such as during failure of cooling fans. The effect of natural convection on the flow and heat transfer in a cavity with two flush mounted heat sources on the left vertical wall, simulating electronic components, is studied numerically and experimentally. The influence of the power distribution, spacing between the heat sources and cavity aspect ratio have been investigated. An analysis of the average Nusselt number of the two heat sources was performed to investigate the behavior of the heat transfer coefficients. The results obtained numerically and experimentally, after an error analysis, showed a good agreement.

Radiation heat savings in polysilicon production: validation of results through a CVD laboratory prototype

This work aims at a deeper understanding of the energy loss phenomenon in polysilicon production reactors by the so-called Siemens process. Contributions to the energy consumption of the polysilicon deposition step are studied in this paper, focusing on the radiation heat loss phenomenon. A theoretical model for radiation heat loss calculations is experimentally validated with the help of a laboratory CVD prototype. Following the results of the model, relevant parameters that directly affect the amount of radiation heat losses are put forward. Numerical results of the model applied to a state-of-the-art industrial reactor show the influence of these parameters on energy consumption due to radiation per kilogram of silicon produced; the radiation heat loss can be reduced by 3.8% when the reactor inner wall radius is reduced from 0.78 to 0.70 m, by 25% when the wall emissivity is reduced from 0.5 to 0.3, and by 12% when the final rod diameter is increased from 12 to 15 cm.

A study in the application of domestic solar assisted heat pumps for heating and cooling

In the present work, the more important parameters of the heat pump system and of solar assisted heat pump systems were analysed in a quantitative way. Ideal and real Rankine cycles applied to the heat pump, with and without subcooling and superheating were studied using practical recommended values for their thermodynamics parameters. Comparative characteristics of refrigerants here analysed looking for their applicability in heat pumps for domestic heating and their effect in the performance of the system. Curves for the variation of the coefficient of performance as a function of condensing and evaporating temperatures were prepared for R12. Air, water and earth as low-grade heat sources and basic heat pump design factors for integrated heat pumps and thermal stores and for solar assisted heat pump-series, parallel and dual-systems were studied. The analysis of the relative performance of these systems demonstrated that the dual system presents advantages in domestic applications. An account of energy requirements for space and hater heating in the domestic sector in the O.K. is presented. The expected primary energy savings by using heat pumps to provide for the heating demand of the domestic sector was found to be of the order of 7%. The availability of solar energy in the U.K. climatic conditions and the characteristics of the solar radiation here studied. Tables and graphical representations in order to calculate the incident solar radiation over a tilted roof were prepared and are given in this study in section IV. In order to analyse and calculate the heating load for the system, new mathematical and graphical relations were developed in section V. A domestic space and water heating system is described and studied. It comprises three main components: a solar radiation absorber, the normal roof of a house, a split heat pump and a thermal store. A mathematical study of the heat exchange characteristics in the roof structure was done. This permits to evaluate the energy collected by the roof acting as a radiation absorber and its efficiency. An indication of the relative contributions from the three low-grade sources: ambient air, solar boost and heat loss from the house to the roof space during operation is given in section VI, together with the average seasonal performance and the energy saving for a prototype system tested at the University of Aston. The seasonal performance as found to be 2.6 and the energy savings by using the system studied 61%. A new store configuration to reduce wasted heat losses is also discussed in section VI.

Radially rotating miniature heat pipes for turbine blade cooling applications

Aerospace turboengines present a demanding challenge to many heat transfer scientists and engineers. Designers in this field are seeking the best design to transform the chemical energy of the fuel into the useful work of propulsive thrust at maximum efficiency. To this aim, aerospace turboengines must operate at very high temperatures and pressures with very little heat losses. These requirements are often in conflict with the ability to protect the turboengine blades from this hostile thermal environment. Heat pipe technology provides a potential cooling means for the structure exposed to high heat fluxes. Therefore, the objective of this dissertation is to develop a new radially rotating miniature heat pipe, which would combine the traditional air-cooling technology with the heat pipe for more effective turboengine blade cooling. ^ In this dissertation, radially rotating miniature heat pipes are analyzed and studied by employing appropriate flow and heat transfer modeling as well as experimental tests. The analytical solutions for the flows of condensate film and vapor, film thickness, and vapor temperature distribution along the heat pipe length are derived. The diffuse effects of non-condensable gases on the temperature distribution along the heat pipe length are also studied, and the analytical solutions for the temperature distributions with the diffuse effects of non-condensable gases are obtained. Extensive experimental tests on radially rotating miniature heat pipes with different influential parameters are undertaken, and various effects of these parameters on the operation of the heat pipe performance are researched. These analytical solutions are in good agreement with the experimental data. ^ The theoretical and experimental studies have proven that the radially rotating miniature heat pipe has a very large heat transfer capability and a very high effective thermal conductance that is 60–100 times higher than the thermal conductivity of copper. At the same time, the heat pipe has a simple structure and low manufacturing cost, and can withstand strong vibrations and work in a high-temperature environment. Therefore, the combination of the traditional air-cooling technology with the radially rotating miniature heat pipe is a feasible and effective cooling means for high-temperature turbine blades. ^

Geothermal district heating networks: modelling novel operational strategies incorporating heat storage

The value of integrating a heat storage into a geothermal district heating system has been investigated. The behaviour of the system under a novel operational strategy has been simulated focusing on the energetic, economic and environmental effects of the new strategy of incorporation of the heat storage within the system. A typical geothermal district heating system consists of several production wells, a system of pipelines for the transportation of the hot water to end-users, one or more re-injection wells and peak-up devices (usually fossil-fuel boilers). Traditionally in these systems, the production wells change their production rate throughout the day according to heat demand, and if their maximum capacity is exceeded the peak-up devices are used to meet the balance of the heat demand. In this study, it is proposed to maintain a constant geothermal production and add heat storage into the network. Subsequently, hot water will be stored when heat demand is lower than the production and the stored hot water will be released into the system to cover the peak demands (or part of these). It is not intended to totally phase-out the peak-up devices, but to decrease their use, as these will often be installed anyway for back-up purposes. Both the integration of a heat storage in such a system as well as the novel operational strategy are the main novelties of this thesis. A robust algorithm for the sizing of these systems has been developed. The main inputs are the geothermal production data, the heat demand data throughout one year or more and the topology of the installation. The outputs are the sizing of the whole system, including the necessary number of production wells, the size of the heat storage and the dimensions of the pipelines amongst others. The results provide several useful insights into the initial design considerations for these systems, emphasizing particularly the importance of heat losses. Simulations are carried out for three different cases of sizing of the installation (small, medium and large) to examine the influence of system scale. In the second phase of work, two algorithms are developed which study in detail the operation of the installation throughout a random day and a whole year, respectively. The first algorithm can be a potentially powerful tool for the operators of the installation, who can know a priori how to operate the installation on a random day given the heat demand. The second algorithm is used to obtain the amount of electricity used by the pumps as well as the amount of fuel used by the peak-up boilers over a whole year. These comprise the main operational costs of the installation and are among the main inputs of the third part of the study. In the third part of the study, an integrated energetic, economic and environmental analysis of the studied installation is carried out together with a comparison with the traditional case. The results show that by implementing heat storage under the novel operational strategy, heat is generated more cheaply as all the financial indices improve, more geothermal energy is utilised and less fuel is used in the peak-up boilers, with subsequent environmental benefits, when compared to the traditional case. Furthermore, it is shown that the most attractive case of sizing is the large one, although the addition of the heat storage most greatly impacts the medium case of sizing. In other words, the geothermal component of the installation should be sized as large as possible. This analysis indicates that the proposed solution is beneficial from energetic, economic, and environmental perspectives. Therefore, it can be stated that the aim of this study is achieved in its full potential. Furthermore, the new models for the sizing, operation and economic/energetic/environmental analyses of these kind of systems can be used with few adaptations for real cases, making the practical applicability of this study evident. Having this study as a starting point, further work could include the integration of these systems with end-user demands, further analysis of component parts of the installation (such as the heat exchangers) and the integration of a heat pump to maximise utilisation of geothermal energy.

A compact shock-assisted free-piston driver for impulse facilities

A free-piston driver that employs entropy-raising shock processes with diaphragm rupture has been constructed, which promises significant theoretical advantages over isentropic compression. Results from a range of conditions with helium and argon driver gases are reported. Significant performance gains were achieved in some test cases. Heat losses are shown to have a strong effect on driver processes. Measurements compare well with predictions from a quasi-one-dimensional numerical code.

Climatic patterns and physical controls of chlorophyll-a in the Northeast Atlantic

Tese de Doutoramento, Física, 17 de Dezembro de 2013, Universidade dos Açores.

Diagnóstico energético e reengenharia do processo de secagem na fábrica de revestimentos

Este trabalho surgiu no âmbito da Tese de Mestrado em Engenharia Química - Ramo Optimização Energética na Indústria Química, aliando a necessidade da Empresa Monteiro Ribas – Indústrias, S.A. em resolver alguns problemas relacionados com as estufas da unidade J da fábrica de revestimentos. Outro dos objectivos era propor melhorias de eficiência energética neste sector da empresa. Para tal, foi necessário fazer um levantamento energético de toda a unidade, o que permitiu verificar que as estufas de secagem (Recobrimento 1 e 2) seriam o principal objecto de estudo. O levantamento energético da empresa permitiu conhecer o seu consumo anual de energia de 697,9 tep, o que a classifica, segundo o Decreto-lei nº 71 de 15 de Abril de 2008, como Consumidora Intensiva de Energia (CIE). Além disso, as situações que devem ser alvo de melhoria são: a rede de termofluido, que apresenta válvulas sem isolamento, o sistema de iluminação, que não é o mais eficiente e a rede de distribuição de ar comprimido, que não tem a estrutura mais adequada. Desta forma sugere-se que a rede de distribuição de termofluido passe a ter válvulas isoladas com lã de rocha, o investimento total é de 2.481,56 €, mas a poupança pode ser de 21.145,14 €/ano, com o período de retorno de 0,12 anos. No sistema de iluminação propõe-se a substituição dos balastros normais por electrónicos, o investimento total é de 13.873,74 €, mas a poupança é de 2.620,26 €/ano, com período de retorno de 5 anos. No processo de secagem das linhas de recobrimento mediram-se temperaturas de todos os seus componentes, velocidades de ar o que permitiu conhecer a distribuição do calor fornecido pelo termofluido. No Recobrimento 1, o ar recebe entre 39 a 51% do calor total, a tela recebe cerca de 25% e na terceira estufa este é apenas de 6%. Nesta linha as perdas de calor por radiação oscilam entre 6 e 11% enquanto as perdas por convecção representam cerca de 17 a 44%. Como o calor que a tela recebe é muito inferior ao calor recebido pelo ar no Recobrimento 1, propõe-se uma redução do caudal de ar que entra na estufa, o que conduzirá certamente à poupança de energia térmica. No Recobrimento 2 o calor fornecido ao ar representa cerca de 51 a 77% do calor total e o cedido à tela oscila entre 2 e 3%. As perdas de calor por convecção oscilam entre 12 e 26%, enquanto que as perdas por radiação têm valores entre 4 e 8%. No que diz respeito ao calor necessário para evaporar os solventes este oscila entre os 4 e 13%. Os balanços de massa e energia realizados ao processo de secagem permitiram ainda determinar o rendimento das 3 estufas do Recobrimento 1, com 36, 47 e 24% paras as estufa 1, 2 e 3, respectivamente. No Recobrimento 2 os valores de rendimento foram superiores, tendo-se obtido valores próximos dos 41, 81 e 88%, para as estufas 1, 2 e 3, respectivamente. Face aos resultados obtidos propõem-se a reengenharia do processo introduzindo permutadores compactos para aquecer o ar antes de este entrar nas estufas. O estudo desta alteração foi apenas realizado para a estufa 1 do Recobrimento 1, tendo-se obtido uma área de transferência de calor de 6,80 m2, um investimento associado de 8.867,81 €. e uma poupança de 708,88 €/ano, com um período de retorno do investimento de 13 anos. Outra sugestão consiste na recirculação de parte do ar de saída (5%), que conduz à poupança de 158,02 €/ano. Estes valores, pouco significativos, não estimulam a adopção das referidas sugestões.

Otimização energética na empresa Simoldes Plásticos S.A.

Mestrado em Engenharia Química - Ramo Optimização Energética na Indústria Química

A case study on the eco-efficiency performance of a composite processing industry: evaluation and quantification of potential improvements

In this study, an attempt was made in order to measure and evaluate the eco-efficiency performance of a pultruded composite processing company. For this purpose the recommendations of World Business Council for Sustainable Development (WCSD) and the directives of ISO 14301 standard were followed and applied. The main general indicators of eco-efficiency, as well as the specific indicators, were defined and determined. With basis on indicators’ figures, the value profile, the environmental profile, and the pertinent eco-efficiency ratios were established and analyzed. In order to evaluate potential improvements on company eco-performance, new indicators values and eco-efficiency ratios were estimated taking into account the implementation of new proceedings and procedures, at both upstream and downstream of the production process, namely: i) Adoption of a new heating system for pultrusion die-tool in the manufacturing process, more effective and with minor heat losses; ii) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.

Saving energy in the GFRP pultrusion process

This study addresses to the optimization of pultrusion manufacturing process from the energy-consumption point of view. The die heating system of external platen heaters commonly used in the pultrusion machines is one of the components that contribute the most to the high consumption of energy of pultrusion process. Hence, instead of the conventional multi-planar heaters, a new internal die heating system that leads to minor heat losses is proposed. The effect of the number and relative position of the embedded heaters along the die is also analysed towards the setting up of the optimum arrangement that minimizes both the energy rate and consumption. Simulation and optimization processes were greatly supported by Finite Element Analysis (FEA) and calibrated with basis on the temperature profile computed through thermography imaging techniques. The main outputs of this study allow to conclude that the use of embedded cylindrical resistances instead of external planar heaters leads to drastic reductions of both the power consumption and the warm-up periods of the die heating system. For the analysed die tool and process, savings on energy consumption up to 60% and warm-up period stages less than an half hour were attained with the new internal heating system. The improvements achieved allow reducing the power requirements on pultrusion process, and thus minimize industrial costs and contribute to a more sustainable pultrusion manufacturing industry.

Assessing the eco-efficiency of a composite processing industry: evaluation and quantification of potential improvements’

In this study, an attempt was made in order to measure and evaluate the eco-efficiency performance of a pultruded composite processing company. For this purpose the recommendations of World Business Council for Sustainable Development (WCSD) and the directives of ISO 14301 standard were followed and applied. The main general indicators of eco-efficiency, as well as the specific indicators, were defined and determined. With basis on indicators’ figures, the value profile, the environmental profile, and the pertinent ecoefficiency’s ratios were established and analyzed. In order to evaluate potential improvements on company eco-performance, new indicators values and eco-efficiency ratios were estimated taking into account the implementation of new proceedings and procedures, both in upstream and downstream of the production process, namely: a) Adoption of new heating system for pultrusion die in the manufacturing process, more effective and with minor heat losses; c) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.

Eco-efficiency approaches towards a sustainable composite materials manufacturing industry’

In this study the potential eco-efficiency performance of a pultrusion manufacturing company was assessed. Indicators values and eco-efficiency ratios were estimated taking into account the implementation of new proceedings and procedures in the production process of glass fibre reinforced polymers (GFRP) pultrusion profiles. Two different approaches were foreseen: 1)Adoption of a new heating system for pultrusion die in the manufacturing process, more effective and with minor heat losses; and 2) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.