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T e r m o g a m m a J o u r n a l o f A p p l i e d S c i e n c e

ARTICLES / CASE STUDIES / NEWS & HIGHLIGHTS / Vol. 2, Issue 2/ May 2019

(2) 2019ISSN 2603-428X

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2CONTENTS

CONTENTS

ARTICLES

1. ANALYSIS OF THE EFFICIENCY OF THERMAL REHABILI-TATION PACKAGES SOLUTIONS FOR THE BUILDING OF THE COUNTY HOSPITAL

/eng. Ion Popa,

eng. Cristina Mihailescu/

Abstract 5 /click to go/ Introduction 6 /click to go/

Brief description of the current buildings 8 /click to go/

Actions and principles for the purpose of identifying solutions for energy rehabilitation and modernization 17 /click to go/

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3CONTENTS

Recommended solution packages 22 /click to go/

Provisional results after implementation of the project 28 /click to go/

Conclusions 30 /click to go/

Bibliographic references 31 /click to go/

2. SYNTHESIS OF HEAT EXCHANGER NETWORKS - SMART OPTIMIZATION PROCEDURES

/Assoc. Daniel Declercq/

Abstract 32 /click to go/

Heuristics 37 /click to go/

Automated procedures. 38 /click to go/

References 51 /click to go/

CASE STUDIES

1. ENERGY EFFICIENCY UPGRADE: FREE STEAM GENERA-TION IN THE BEVERAGE INDUSTRY, THE MENA REGION

Background 57 /click to go/

Site description 57 /click to go/

KitCOG system: Termogamma proposed solution 58 /click to go/

4CONTENTS

Summary of the main advantages 59 /click to go/

System components 60 /click to go/

Technical datasheet 61 /click to go/

Projected results 64 /click to go/

2. ENERGY EFFICIENCY UPGRADE: WASTE HEAT RECOV-ERY AND FREE HOT WATER TO ELECTROMECHANICAL MANUFACTURING COMPANY, SWITZERLAND

The Group 65 /click to go/

Description of Termogamma SAvER solution 66 /click to go/

Short description of Termogamma installation in Switzerland 67 /click to go/

Third SAvER system 69 /click to go/

CONTACTS 70 /click to go/

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ANALYSIS OF THE EFFICIENCY OF THERMAL REHABILITATION PACKAGES SOLUTIONS FOR THE BUILDING OF THE COUNTY HOSPITAL

eng. Ion Popa,

eng. Cristina Mihailescu,

Abstract. This paper examines the research on the most ef-ficient rehabilitation of the Piatra Neamt county emergency hospital for the different types of structures: C1 structures - the Psychiatric Department; C2 structures - the Patholog-ical Anatomy and Forensic Medicine Department; C32 struc-tures - The Infectious Diseases Department. A lot of re-strictions and rules were taken into consideration because the funds were provided by a funding program established by the design blueprint: the Regional Operational Program 2014-2020: specific conditions for accessing the funds within the calls for projects under por/2016/3/3.1/b/1/7 ar-eas and por/2016/3/3.1/b/1/b; regional operational program 2014-2020; priority axis 3, investment priority 3.1 operation b –public buildings. This research and the project related to it obtained the evaluation score of 83.67 points out of 100.

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Key-words: hospital, thermal rehabilitation, modernizing in-stallations, high efficiency cogeneration

1. INTRODUCTION. GENERAL PRESENTATION – THE

STATE OF PLAY

The Piatra Neamt County Emergency Hospital is the biggest hospital in the county of Neamt, under the management of the Neamt County Council. It has been operating on the current location since 1935 and includes 30 sections and departments of the Dialysis Center with 12 machines, of the Emergency Room, as well as departments for clinical-non-clinical exams. The Outpatient Care is also part of the hos-pital, including all its medical and surgical units; plus, a pe-diatric and adults’ dentistry practice which also ensures the treatment of emergency cases.

The activities of the Piatra Neamt County Emergency Hos-pital are organized in 41 structures, groups of buildings, each of which has a different role, medical services con-structions and services.

The design blueprint consists of 3 existent buildings: C1 structures - the Psychiatric Department, C2 - the Patholog-ical Anatomy and the Forensic Medicine Department, C3 the Infectious Diseases Department.

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Images of the situation of the buildings

Fig. 1 a) The situation plan

Fig. 1 b) The photo of the buildings

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The assembly is in the climate zone III.

Fig. 2 Cadastral site plan - PIATRA NEAMT COUNTY EMER-GENCY HOSPITAL:

2. BRIEF DESCRIPTION OF THE CURRENT BUILDINGS –

FEATURES

C1 structure - the Psychiatric Department:

The C1 structure is a building for company accommodation transformed into a hospital body, ex estimated executed in 1968.

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The shape of the body is rectangular. The sizes are 11.25m x 28.05m;

Height regime: basement+ ground floor+4 floors; heated basement. Built area: 316 m2, Built surface : 1896 m2; Sutil heated = 1662.40 m2;

The superstructure is composed of prefabricated surface elements – big panels – of walls and slabs, the structural system is of reinforced concrete orifice type;

The occupation regime -24h/24 – medical practices and rooms with hospitalized patients;

Category of building according to destination – healthcare building

Fig. 3 Installations used in the buildings under analysis

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How to provide utilities

- Heating: - hot water heating - central wall mounted in the building.

- Hot water: - mixed source heating agent from central wall and solar installations * (solar panels are mounted on the building's terrace)

* For the existing building, when calculating the hot water consumption from the renewable source, the metered con-sumption of the solar system for two years has been taken into account.

- SEN electricity lighting;

- It does not have air conditioning or mechanical ventilation;

C2 structure - the Pathological Anatomy and Forensic Med-icine Department

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This is a multiple use building. The morgue of the hospital is in the basement, then there are the ground floor and the floors, the offices and specific laboratories. It was built in 1974.

The shape of the body C2 is rectangular.

Height regime: Basement + Ground floor + 2 floors; heated basement;

Built area: 280 sqm;

Built surface: 1120 sqm;

Sutil heated: 921.43 sqm;

The construction is made of reinforced concrete in gravitational solution and 28 cm thick vertical masonry load-bearing walls, masonry confined with concrete pits.

The roof skirting is made of wood and is supported by a structure of props, pans, coffins and rafters; the building was designed and executed with a terrace floor, afterwards the architectural solution of the roof was changed, a roof and a low-rise bridge were built.

The building was included in the destination category of health-care building; the various activities carried out in the building re-quire different operating regimes and occupations. This category was chosen because of the use of the building associated mainly with healthcare. The minimum energy efficiency requirements

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for healthcare buildings were achieved through rehabilitation.

How to provide utilities in building C2:

- Heating: - hot water - central heating, natural gas, con-densing - 3 pieces, located in the basement. The operation is intermittent, with a guard temperature of 15 ° C, during the period when the building is not occupied. The inter-mittent program is applied manually, without automation; - Hot water - It is locally prepared with a boiler room of tech-nical space and a storage tank of 200 lt;


- It has no air conditioning nor mechanical ventilation;

C32 Structure - The Infectious Diseases Department

Corp C32 is estimated to have been built in 1971, the building is designed to be used as a hospital, for the provisions of medical services, the Department of Infectious Diseases.

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The shape of the body C32 is rectangular.

Height regime: Partial basement + Ground floor + 2 floors; heated basement;

Built-up surface: 1522 sqm;

Sutil heated: 1253.36 sqm;

The structural system is made of reinforced concrete in gravitational solution and masonry bearing walls with rare verticals, masonry confined with concrete piles.

The roof skirting is made of wood and is supported by a structure of props, pans, beams and rafters and has the concrete floor above the 2nd floor.

How to provide utilities in building C32:

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- Heating: - The energy source for the space heating is lo-cated in the quaternary thermal power station of the Piatra Neamt County Emergency Hospital. The building is connected to the source via a pre-insulated pipe network with faulty installation. The heating agent is supplied with a 95/75 C hot water boiler with natural gas fuel.

- The hot water is centrally prepared in the same quater-nary central heating source, the primary heat supply being hot water from natural gas boilers, it is heated in plate heat exchangers and the gathered in storage vessels; There are hot water solar panels installed on some buildings in the complex. There is a heat collection thermal point through a sub-dimensional and poorly isolated air network. Some panels are faulty and are out of use. No expert installation expertise has been made to estimate the percentage of hot water obtained from solar energy in the total consumption of buildings connected to the thermal point. Consequently, for C32, it was considered that hot water is provided 100% from the classic source - natural gas boilers;


- It does not have air conditioning or mechanical ventilation;

In accordance with Art. 8 of the Order no. 2641/2007, the audit report evaluated the consumptions for the building

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utilities identified at the date of the data collection in situ.

As there was access to the financing program for all three buildings at the same time, the project indicators were first calculated individually and then calculated for the three buildings. Spatial consumption was calculated by applying weighted average for the three buildings.

The calculations of the indicators for existing and buildings in total are contained in the table below:

Units C1 C2 C3 Total

Area m2 1,662.40 921.43 1,253.36 3,837.19

Annual amount greenhouse gases - eqivalent tone CO2

The initially value – date start project

Tone CO2/an

136.35 91.26 167.88 395.49

Annual consumption primary energy - kWh/an


kWh/an 940,852 548,755 1,009,782 2,499,389

Annual consumption primary energy (fossil sources) - kWh/m2/an - total

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kWh/m2/an 490.53 590.72 805.66 617.52

Annual consumption primary energy (fossil sources) - kWh/m2/an - total: for heating


kWh/m2/an 266.23 463.54 460.24 376.98

Annual consumption primary energy (renewable sources) - kWh/an - total


kWh/an 125,395 0.00 0.00 125,395

Annual consumption primary energy (renewable sources) - kWh/an - total: for heating


kWh/an 0.00 0.00 0.00 0.00

Annual consumption primary energy (renewable sources) - kWh/an - total: for domestic hot water


kWh/an 125,395 0.00 0.00 125,395

Annual consumption primary energy (renewable sources) - kWh/an - total: for lighting


kWh/an 0.00 0.00 0.00 0.00

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3. ACTIONS AND PRINCIPLES FOR THE PURPOSE OF

IDENTIFYING SOLUTIONS FOR ENERGY REHABILITA-

TION AND MODERNIZATION

In order to achieve the goals specified in the financing guide and a score that would allow direct financing for the project, the design team considered the following:

1. A proposal for solutions for the building envelope which exceeds the standard minimum resistance and the maxi-mum annual primary energy consumption of 149 kwh / m2 (the evaluation was made with the thermal preparation solution existing at the date of the expert's examination)

2. Verifying each building’s need for air-conditioning instal-lation - in view of the existing location, cardinal directions, shading due to the land and neighboring buildings, with the proposed thermal protection. The buildings are situated in the climatic area III, climatic data were used for three lo-cations - conf.MC 001/6. Conclusion: No building needs air conditioning, given the westward shading of the glazing.

3. Ensuring a proper ventilation rate by means of local equipment with CO2 and humidity sensors; the technical file specifies that such equipment recovers the heat from the exhaust air. At this stage of the analysis, the team of specialists in resistance, architecture and installations es-

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tablished the location of the machinery, the type and the technical characteristics in accordance with the provisions of law.

4. A study of the "Energy Efficiency Improvement Program for Localities with a Population of More than 5,000 people", carried out in accordance with Article 9 Paragraph (12) of the Energy Efficiency Law no 121/2014, approved by the Lo-cal Council of Piatra Neamt, filed at ANRE. We wanted to implement and develop the measures provided for public buildings and the policy providing for the development of renewable energy in the area. Only general information on this was available. For access to this financing program, a local energy strategy is required, regardless of its title, assumed by the UAT, and there is no specific requirement for the content and observance of the proposed objectives and actions; I consider this to be a deficiency in the funding program, i.e. these strategies, which should be prepared by professional teams and be used for the pre-selection and ranking of public buildings in order to provide access the financing programs for those most suited to their opera-tional requirements. They are needed to avoid the rejection of the project as ineligible, at an early stage, and to avoid non-compliance with indicators, after the stage of imple-mentation of this program.

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In this case, we have reconsidered the component of this local energy strategy, on the entire energy contour of the Neamt County Hospital, establishing:

` Connection of the buildings’ subject to the project, to a centralized, energy-efficient system - cogeneration central and the execution of a pre-insulated heating network (return / return heating, acm and acm recircu-lation) with metering for each building.

` A solution was developed by a specialized design team - SC EnergoFOR, collaborating in the elaboration of a complex feasibility study. Considering the technical, economic and sustainability aspects, it aimed at the replacement of the existing power supply with the co-generation source and provided that:

` The electricity produced in the cogeneration unit can-not be supplied in SEN – it must be consumed in the energy contour.

` All heat demanded (according to I13 norm) is fully sup-plied for the three buildings.

` Domestic hot water supply - the only utility that can be provided from the renewable source (solar) so that, at the end of the project implementation, at the financing request level (for the three buildings), it accounts for at

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least 10% of the total energy consumption primary for all utilities (heating, acm, lighting and ventilation).

Thus, by evaluating the centralized source, the existing re-newable sources (for which technical expertise of energy efficiency was needed) and the electric energy consump-tion, the size of the cogeneration unit was estimated with a view to high energy efficiency production. Sizing was based on the need for electricity across the entire energy outline during the summer. (based on the actual consumption, three years ago).

The internal combustion engine is recommended to be used. It is proposed that the size of the cogeneration plant should be based on both the analysis of the electrical and thermal energy requirements in view of the specific characteristics of consumer needs at the site.

` The cogeneration plant will be a module that can sup-ply electricity and thermal agent for the preparation of the heating medium to temperatures of 90/70 degrees C and domestic hot water with the temperature accord-ing to the applicable sanitary standards (55 ... 60 ° C)

` The cogeneration plant will be able to operate at partial loads of 50...100%, with a global efficiency of over 85%;

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` The minimum electrical power delivered from the in-stallation is 110kW (corresponding to the minimum pow-er absorbed according to the consumption history);

` The amount of electricity delivered will cover at least 60% of the site's electricity demand;

` The installation shall observe the technical connection conditions corresponding to synchronous generators of category A12 (for interconnection to the electrical installation of the hospital, which is connected to the public distribution networks);

` The regulation of the protection and automation system will be in line with the requirements of the distribution operator and will ensure the delivery of electricity, only to the facilities of the hospital unit, without the possi-bility of supplying electricity in the distribution electric networks;

` The cogeneration module will be equipped with me-tering systems that will allow recording and storing the hourly data on fuel consumption and electric and ther-mal energy production.

Two scenarios were identified in the energy audit reports – they were identified as solutions packages, scenarios

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that were included in the DALI memorandum compiled. Decision number 907/2016 on the phases of elaboration and the framework content of the technical and economic documentation related to the public-financed investment objectives/ projects.

4. RECOMMENDED SOLUTION PACKAGES

Solution packages were established, following the econom-ic analysis, for each building.

Recommended solutions for the building envelope:

` Thermal-insulation of the elements in contact with the soil:

h The plate on the ground under CTS of the warmed basement.

Increasing the thermal resistance of the slab on the ground placed under CTS by placing on top of the ground floor a 5-cm ground floor layer extruded polystyrene protected by an armour.

h Plate on the ground on CTS

To improve the thermo-technology of the ground plate, we recommend the following: - providing, on the outer face of the socket, a 10-cm thermo- insulating layer with moisture resistant properties, made of extruded polystyrene plates;

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the thermal insulation layer will be fixed mechanically and glued and will be protected externally by a layer of reinforced plaster in height. The heat insulating layer will be applied at least 30 cm above the top part of the reinforced concrete slab and at least 30-40 cm below the CTS at the bottom.

h Reinforced concrete walls of the basement that are in contact with the soil on the outer perimeter of the building.

Increasing thermal-resistance by thermal-insulation on the outside with extruded 10 cm thermo thick polystyrene, the thermal-insulation will be protected with moisture-resis-tant plaster.

h Thermo insulation of the outer reinforced concrete walls of the demisol.

The measure provides thermal insulation of the walls of the demisol with thermosystem made of 10 cm thick extruded polystyrene thermal insulation material, the thermal insula-tion will be protected with moisture-resistant plaster.

` Heat insulation of exterior brick masonry walls or con-crete slabs.

Increasing the thermal resistance by thermal insulation on the outside with thermal insulation material thermal - insu-

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lation basalt façade in composite system - thermal insula-tion thickness of 10 cm.

Exterior plaster will be applied for protection. When apply-ing the thermosystem, there will be a particular focus on improving the effects of structural thermal bridges.

The bowl, formed by the 0th floor, which comes out in the console with respect to axis A, between the axles 1 and 2, will be thermo-insulated at the bottom with a thermosystem whose thermal insulation thickness will be 20 cm.

` Thermal insulation of the floor over the last floor to the unheated bridge.

Increasing the thermal resistance of the floor above the top level by fitting a heat insulation layer of adequate quality and thickness above the new minimum energy performance re-quirements for buildings. It is recommended to cut the layers to the reinforced concrete slab. The new layers to be provided are: support equalization screed, diffusion layer, decompres-sion, compensation, vapor barrier, thermo insulating thermal insulation basalt wall thickness 30 cm Dual Density, protec-tion thermo-insulation - reinforced plaster thickness 5 cm.

` Replacement of extrinsic exterior carpentry with energy efficient carpentry.

Replacement of existing PVC joinery on the facades, with energy-efficient carpentry. The thermal resistance of the

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recommended carpentry (frame and glass) is 1 [m2K / W]. The panel will be provided with hygroscopic grids. The ex-terior carpentry will be placed on the outside of the walls if this is possible considering the technical solution for resis-tance and architecture. It is recommended to mount shad-ing devices on the western glazing.

Recommended solutions for building installations: The I RES Installations package.

Providing comfort in the building by providing additional facilities to existing utilities: heating, domestic hot water and lighting of some ventilation systems with heat recovery from the exhaust air.

` Measures at the level of sources of energy production: Substitution of the energy sources used in the building.

Thermal and electric energy

In the quaternary source, the production of heating agent and the preparation of hot water, complementary to the solar system, will be provided by a natural gas cogeneration module - high energy efficiency equipment. Both thermal and electric energy will be used for heating in the building, heat recovery - for hot water supply, lighting and ventilation.

Hot water for consumption

Partial substitution of the energy source for hot water - it is

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recommended to provide a solar installation located on the roof of the building, so as to ensure an average of 75% of the annual consumption of hot water from unconventional sources; the complementary source will be the cogenera-tion module in the quartz plant and the existing solar panels that serve the entire complex.

` Measures in the external distribution network

Heating agent and hot water.

The solution concerns the connection of the building through a pre-insulated piping system - used for hot water heating / return water, hot water and hot water recirculation - to the quaternary central heating station of the Neamt Municipal Hospital where the cogeneration module is installed.

It is proposed to install at heating level connection heating medium and hot water - the installation of thermal energy measurement systems.

` Measures at the level of indoor distribution and use of appliances

Heating

Replacement of the internal distribution network of the heat-ing agent, heating columns and static bodies in order to adapt to the new heating demand resulting from the application of

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the rehabilitation and modernization solutions to the tire el-ements and the effects of the ventilation with heat recovery.

Thermal insulation of distribution pipes (heating medium) from unheated spaces.

Provision of static bodies with thermostatic heads.

Hot water for consumption

Replacing the internal distribution network and the hot water columns.

Thermal insulation of distribution pipes (hot water) in unheat-ed spaces. Equipping the hot water supply system with high quality fittings with limitation of water consumption.

Lighting

Replacing the internal electric lighting network, resizing it as a result of the use of led lighting.

Replace fluorescent luminaires with LED bulbs and equip joint spaces with presence sensors.

` Ensure the ventilation rate - by installing local ventila-tion systems with heat recovery.

It is recommended to provide a ventilation system with heat recovery - ensuring fresh air intake for physiological comfort through ventilation, with heat recovery from the exhaust air, providing equipment with 80% minimum energy efficiency.

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5. PROVISIONAL RESULTS AFTER IMPLEMENTATION

OF THE PROJECT

The Energy Audit Reports estimate the following results in terms of individual buildings and in total, cumulatively.

The results are available in the table below:


Area m2 1,662.40 921.43 1,253.36 3,837.19

Annual amount greenhouse gases - eqivalent tone CO2

The final value – date start project

Tone CO2/an

49.86 29.10 33.53 112.49

The final value date start project-Specific

Tone CO2/m2/an

29.99 31.33 26.74 29.25

minimum requirement: the value < 32.00[Tone CO2/m2/an] – requirement

Annual consumption primary energy - kWh/an


kWh/an 466,515 173,145 340,709 980,369

Reducing con-sumption % 50.41 68.44 66.26 60.78

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Annual consumption primary energy (fossil sources) - kWh/m2/an - total


kWh/m2/an 159.94 167.26 147.35 157.59


Specific annual primary energy consumption (from non-renewable sources) (kWh / m2 / year)], of which: for heating / cooling


kWh/m2/an 66.89 89.23 45.18 65.16


Annual consumption primary energy (renewable sources) - kWh/an - total


kWh/an 200,635 17,771 156,031 374,437

Percentage se-cured by renew-able sources

% 43.01 10.26 45.80 38.19

minimum requirement: the value >10 [%]–requirement

Annual consumption primary energy (renewable sources) - kWh/an - total: for heating


kWh/an 0.00 0.00 0.00 0.00

Annual consumption primary energy (renewable sources) - kWh/an - total: for domestic hot water

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kWh/an 200,635 17,771 156,031 374,437

Annual consumption primary energy (renewable sources) - kWh/an - total: for lighting


kWh/an 0.00 0.00 0.00 0.00

6. CONCLUSIONS

The project indicators, required for funding under Axa3.1B, could be achieved through the application of classical reha-bilitation solutions for the building envelope, while increasing the capacity to produce hot water from renewable source (solar) and adopting high efficiency cogeneration as a source of energy production.

The preliminary assessment made by the energy auditor in collaboration with all the design team, the choice of feasi-ble technical solutions, in line with the real potential of the area, and the adaptation of the project to the local energy efficiency strategy, lead to a decrease in the rejection rate of projects to the implementation and contribute to avoiding unnecessary documentation that involves important time and financial resources.

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7. BIBLIOGRAPHIC REFERENCES

1. Specific Guidelines POR / 2016/3 / 3.1 / B / 1 / 7REGIONS and POR / 2016/3 / 3.1 / B / 1 / BI - Priority Axis 3 - Supporting the transition to a low-carbon economy, Operation B - Public Buildings

2. Energy audit reports

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SYNTHESIS OF HEAT EXCHANGER NETWORKS – SMART OPTIMISATION PROCEDURES

Daniel Declercq

[email protected]

Keywords: pinch analysis, synthesis of heat exchanger net-works

Abstract. The synthesis of heat exchanger networks is still a challenging task. Pinch technology, apart from the analysis itself, has also established a number of fundamental rules for the design of the heat exchanger network to accomplish the energy targets. These rules, however, are not always conclu-sive especially in the case of stream splits and although the results can meet the energy targets, such results are not al-ways optimal in terms of overall cost.

A few alternative procedures will be discussed hereafter and illustrated by the application on a 4-streams example origi-nally proposed by Shenoy [1]. The example has 2 hot steams, 2 cold streams, a hot and a cold utility; the data set is given in Table 1.

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Table 1: Data set example.

Tsupply

°CTtarget

°C

Heat kW

DT-Shift

K

U*f

kW/K,m²

Descript

-

175 45 1300 6.5 0.2 H1

125 65 2400 6.5 0.2 H2

20 155 2700 6.5 0.2 C1

40 112 1080 6.5 0.2 C2

180 179 360 0.2 Heating

15 25 280 0.2 Cooling

Cost data

Heating: 120 $/kW,year Cooling : 10 $/kW,year Area Cost ($) = 30000 + 750 x Area 0.81

Annual cost factor = 0.3221 Annual Area Cost ($/year) = 9663 + 241.575 x Area 0.81

Energy consumption in the table corresponds to an overall DTMin of 13 K. Composite curves are shown in Figure 1.

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Figure 1: Composite Curves.

The annual cost factor Af was calculated according to the formula Af = (1+i)n/n whereas i is the interest rate (10%) and n is the project life time (5 years). It should be understood that this annual cost factor is arbitrary and does not correspond to the annuity of the investment required to generate a Net Present Value equal to that investment. However, these cost data have been used in the scientific publications and, therefore, they have been withheld for further comparison.Trade-off in classic pinch analysis is done on the basis on a uniform DTMin with a segregation of the problem above

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and below the pinch. Here, trade-off is done on the basis of the heat load, once with segregation at the pinch and once without such segregation, assuming one single system. The results, shown in Figure 2, give a total cost target of 239,450 $/year for a heating load of 360 kW and a network with 6 units (2 systems) and a total cost target of 226,111 $/year for a single system with 5 units, also for a heating load of 360 kW.Figure 2: Trade-off energy versus capital as a function of the heating load.

The results developed by Shenoy are shown in Table 2, which has been completed with results obtained after further op-timization of the networks by incremental evolution.

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Table 2: Results as reported by Shenoy and after optimisa-tion by incremental evolution.

Results pinch

designReported Optimised

Heating #Units #Splits Cost Heating #Units #Splits Cost

Alternative kW - - $/year kW - - $/year

S1 360 6 1 245,828 371.9 6 1 242,336

S2 360 6 1 248,238 388.2 6 1 241,849

S3 360 6 2 240,025 353.3 6 2 238,173

S4 360 6 2 261,423 384.7 6 2 251,218

The optimised networks of Table 2 are shown in Figure 3. They can be further improved by application of specific procedures as explained and illustrated hereafter. Alterna-tively, instead of following the pinch design rules directly, heuristics can be used whilst taking into account the insight gained from pinch technology.

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Figure 3: Optimised networks of Table 2.

HEURISTICS

A network with minimum cost can be generated with a smart tick-off procedure respecting the following rules and optimising the network so obtained:

` Rule 1: satisfy the smallest heat load with one unit;

` Rule 2: match a stream stretching over the pinch with a (branch of a) counterpart also stretching over the pinch;

` Rule 3: no heating below the pinch, no cooling above the pinch, no heat transfer across the pinch.

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` C2 on a branch H2b of H2 (rules 1 and 3);

` H1 on a branch C1a of C1 (rules 1 and 2);

` Cooler on the cold side of branch H2a;

` Heater on the hot side of branch C1b (rule 3);

` Fill in the remaining match H2a – C1b.

The result is a network with 5 units and 2 splits with a cost of 230,549 $/year, evolving to 227,544 $/year after further optimisation by incremental evolution. Relocation of the cooler from branch H2a to branch H2b and further optimis-ation leads to a minimum cost network with a heating load of 384.7 kW, 5 units, 2 splits and a cost of 226,721 $/year, which is within 0.27% of the target. This network, shown in the overview in Figure 9 reference Alt.8b, can also be devel-oped by automated procedures.

AUTOMATED PROCEDURES.

Several alternative networks can be developed by using simple automated procedures. The grid from the analysis contains 7 bands (superstructures) of which bands 5, 6 and 7 can be merged (Table 3).

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Table 3: Stream Grid diagram reduced to 5 bands.

Tsupply

°C

Ttarget

°C

Heat

kW

De-

script

mcp

kW/KBands & temperatures (°C)

1 2 3 4 5

180 179 360 H1 360 180 179

175 45 1300 H2 10 175 125 74.6 68.6 45

125 65 2400 C1 40 125 74.6 68.6 65

20 155 2700 C2 20 155 137 112 40.0 25.0 20

40 112 1080 Heating 15 112 40.0

15 25 280 Cooling 28 25.0 15

The following network alternatives can be generated using Linear Programming (LP):

` Alt.1: starting with the 5 bands, merging bands 3 and 4 (Table 4) and applying LP;

` Alt.2: as Alt.1 with forbidden match between H1 and C2, so avoiding a split on cold stream C2. In both cases, af-ter optimisation, the cooling duty will be concentrated on hot stream H1.

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Table 4: Stream Grid diagram reduced to 4 bands (Alt.1and Alt.2)

Tsupply

°C

Ttarget

°C

Heat

kW

De-

script

mcp

kW/KBands

1 2 3 4 5

180 179 360 H1 360 180 179

175 45 1300 H2 10 175 125 74.6 45

125 65 2400 C1 40 125 74.6 65

20 155 2700 C2 20 155 137 112 40.0 20

40 112 1080 Heating 15 112 40.0

15 25 280 Cooling 28 15

The initial networks are shown in Figure 4.

With LP applied to four integration bands, a minimum num-ber of units is obtained within each band; consequently, the total number of units (8) is higher than in a pinch design (6).

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Figure 4: Initial networks for alternatives Alt.1 to Alt.4.

For the 4 given alternatives, the number of bands of the grid can be reduced from 4 to 3 by merging bands 1 and 2, put-ting the heater and the first exchanger on cold stream C1 in parallel, resulting respectively in alternatives Alt.5 to Alt.8.

The initial networks can be optimised by incremental evo-lution and simplified by distortion of the solution space and nodes between consecutive split configurations can be refined by smart node arrangements. The procedures are explained hereafter.

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a) Incremental evolution.

For an initial network that contains a path between a heater and a cooler, a trade-off between energy and capital can be made by adjusting the load on the heater whilst establishing and maintaining the heat balance over the path. The num-ber of variables (degrees of freedom) equals the number of paths. Also in case of loops in the network, the heat loads of the units in a loop can be adjusted whilst maintaining the heat balance in the loop. The number of variables (degrees of freedom) equals the number of loops. Depending upon the cost structures, these trade-offs might lead to simplifi-cation of the network and reduction of the number of units.

b) Distortion of the solution space.

If the cost structure has the form C = A + B x AreaC, then for a network that contains more heat exchanger units than the minimum there is a potential for reducing that number which might lead to further reduction of the total cost. The cost function favours unequal unit areas and this effect is stronger with lower values of the exponent c; a lower value will tend to kick out the smaller units. This is illustrated for the pinch design network S3 after optimisation by incre-mental evolution (Figure 5a). In the normal case, during in-cremental evolution of the unit A1, the solution is trapped in

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the minimum of the trough of the red cost curve (a sub-op-timum) as shown in Figure 6. Reduction of the exponent c from 0.81 to e.g. 0.4 will pull down and distort the solution space. After pull-down, application of incremental evolution at constant heating will let the previous solution run further down out of the original trough into a new trough without the exchanger A1. This is shown in the blue curve in Figure 6, where for reason of comparison the fix cost has been in-creased to obtain the same total cost as for the normal case for the given heating load.

Figure 5a: Network before pull-down Figure 5b: Network after pull-down

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Figure 6: Cost evolution in the normal case and the pulled-down case.

The solution space can now be restored by going back to the original value for the exponent c and incremental evolution, now at variable heating, will generate a new optimum with one heat exchanger unit less as shown in Figure 5b (the load of unit A1 has been merged into unit A2.

Instead of being pulled-down, the solution space can also be pushed up by increasing the value c to 1; incremental evolution at variable heating might push the solution into an adjacent trough and after restoring the solution space, this configuration can be used as a starting point for a new op-

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timisation or for a new pull-down and incremental evolution at constant heating.

c) Smart node.

A node between consecutive split configurations can be re-fined by a smart node arrangement as shown in Figure 7 (A: standard node, B: smart node, C: double smart node). Smart nodes enable the merger of 2 heat exchangers that are on the same stream branches in adjacent integration bands and other arrangements as shown further in the examples.

Figure 7: Simple node and smart nodes

The 3 bands grid can be reduced to 2 by merging bands 2 and 3. The resulting networks develop into alternatives already generated by the procedures mentioned earlier. A particu-

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lar network with a double split on hot stream H2 in band 2 is shown in Figure 8; this network can successfully be devel-oped into the network alternative Alt.8b using smart node configurations.

Figure 8: Example of an initial network for 2 integration bands with simple and smart nodes.

The results of application of the various procedures are sum-marized in Table 6; related networks are shown in Figure 9.

The procedures described combine relaxation techniques of classic pinch technology and capabilities of Mixed In-teger Non-Linear Programming (MINLP) for simplification of networks.

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Table 6: Optimised networks.

°1) sequence: initial network / push up / pull down / restore

°2) sequence: optimise / pull down / restore

°3) sequence: optimise / pull down / restore / pull down / restore

°4) sequence: optimise / push up / pull down / restore

°5) sequence: initial network / push up / pull down to 5 / restore

°6) sequence: initial network / push up / pull down to 6 / re-store / pull down to 5 / restore

°7) network identical with the network reported by Rezaei

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Figure 9: Networks of the various solutions.

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Figure 9: Networks of the various solutions (continued).

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Figure 9: Networks of the various solutions (continued).

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57CASE STUDIES

CASE STUDYby Termogamma

ENERGY EFFICIENCY UPGRADE: FREE STEAM GENERATION IN THE BEVERAGE INDUSTRY, THE MENA REGIONBACKGROUND

In many areas with frequent and extended blackouts or areas with-out centralized power distribution network, one of the few cost-ef-fective options for power generation remains diesel generators (gensets). Uninterrupted power supply is especially important for the manufacturing industries, which cannot afford to lose work hours, respectively revenues, on a regular basis.

There are such areas all over the MENA countries, which actually in-vest and improve their power generation and distribution networks, but there is still a lot to do. In the meantime, many companies have installed gensets to provide the energy needed for their manufac-turing processes.

SITE DESCRIPTION

The case explores the potential energy efficiency upgrade of a bev-erage factory in MENA which operates continuously - 24 hours per day, more than 335 days per year.

58CASE STUDIES

As it is in an area without centralized power supply, it generates its electrical energy on site through a diesel generator of 502 kW, oper-ating 12 hours per day with an ongoing manufacturing process.

The manufacturing process also consumes large quantities of ther-mal energy in the form of steam, i.e. 8 ton/hour of steam at 8 bar. This thermal energy is currently generated by heavy oil boilers.

KitCOG SYSTEM: TERMOGAMMA PROPOSED SOLUTION

The energy and cost-saving solution proposed by Termogamma for this factory concerns the implementation of a customized waste heat recovery system, model KitCOG-220/Steam, which will recov-er the large amount of heat produced (and nowadays completely wasted) by the diesel generator while producing electricity. The new system will allow the factory to save the diesel fuel which it currently consumes to generate part of its thermal energy.

KitCOG-220/Steam will be customized to meet exactly the thermal energy needs and resources of this factory. Thus, the system cou-pled with the genset will be able to recover 220 kW of waste heat delivering it as steam (approximately 310 kg/h, at 8 bar).

All components of the system will be completely integrated at the manufacturer’s site and delivered to the beverage factory ready for operation PLUG&PLAY system. The only installation work that should be performed on site is the connection between the new system and the existing steam distribution pipe network.

59CASE STUDIES

SUMMARY OF THE MAIN ADVANTAGES OF KitCOG

` Free energy – steam production: while the generator produces electricity, it develops waste heat in the ex-haust gases and in the engine itself. It is recovered as steam (8 bar), and then delivered where needed. The steam is therefore available at 0 cost, which means im-mediate savings on fuel.

` Fast installation: all components needed for the sys-tem’s operation (pumps, valves, sensors, electric boards, pipes, heat exchangers…) are included, installed and connected inside a special skid, which reduces to a large extent the installation and connection time at the client’s site.

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` Automated operation: the system operates automati-cally and continuously with minimum operator supervi-sion. It also integrates a Remote monitoring and control system, providing constant performance tracking and historic record of key parameters (temperatures, batch history, etc.).

SYSTEM COMPONENTS

Steam Generator

The steam generator is placed as close as possible to the genset, at the beginning of the exhaust gases discharge cir-cuit. It recovers heat from the genset’s exhaust gases and uses it to convert the steam generator’s water into steam.

Economizer

The economizer is placed just after the steam generator and uses the residual heat of the genset’s exhaust gases. It consists of an exhaust gases/water heat exchanger and is used to pre-heat the steam generator’s inlet water.

Exhaust Gases Discharge System

Once all the waste heat is recovered, the genset’s exhaust gas-es are discharged directly into the atmosphere through the ex-haust system. The composition of this system is highly specific for the type of installation to be carried out at the user site.

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Control and Monitoring system

The brain of kitCOG, designed with the utmost attention to the genset’s operation safety. Key parameters of the system are constantly monitored. Temperatures, pressures, flows, etc are controlled continuously, checking the good opera-tion of kitCOG, and ready to operate any safety measures if and when needed.

TECHNICAL DATASHEET

KITCOG - 220/s Value Unit

OUTPUT PARAMETERS

Steam capacity220310

kWkg/h

Steam pressure 8 bar

Exhaust gases outlet temperature 180 °C

62CASE STUDIES

KITCOG - 220/s Value Unit

INPUT PARAMETERS

Exhaust gases INLET temperature (from client genset)

465 °C

Exhaust gases INLET flow (from client genset)

2,408 kg/h

Inlet water temperature to steam generator 65 °C

LAYOUT AND DIMENSIONS

Kind of installation INDOOR STD

Width 2,800 mm

Length 2,500 mm

Height 2,300 mm

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Technical data and dimensions are indicative only and subject to changes without notice.

3D layout of the kitCOG system (Layout is not representative of the system described in this document. It shows a general view as an example).

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PROJECTED RESULTS

The KitCOG 220/Steam system will recover annually 884 MWh of thermal energy (as steam at 8 bar), thus avoiding the consumption of more than 88,440 litres of heavy fuel oil and saving up to 251 tons of CO2 emissions. The emissions are particularly important in the MENA countries, as various studies have shown that the lack of centralized power supply there contributes significantly to their worsened air quality.

Based on the available information on the factory’s annual work hours and energy-related costs (heavy oil, electricity and water), the calculated payback period of the new sys-tem is less than three years, whereas its standard life-cycle is more than ten years.

65CASE STUDIES

CASE STUDYby Termogamma

ENERGY EFFICIENCY UPGRADE: WASTE HEAT RECOVERY and FREE HOT WATER TO ELECTROMECANICAL MANUFACTURING COMPANY, SWITHERLANDThe Group

The Swiss company is part of a group founded in Luxem-bourg in the late 70’s and it has been manufacturing elec-tromechanical products for the automotive and household appliance industries. The group has a very large portfolio of products which covers components for temperature control and micromotors such as temperature sensors, fan motors, actuators for various applications or DC and gear motors. Today, it is a relevant international group with more than ten production sites; it is the worldwide leader in specific auto-motive systems such as pumps and other components, and it is one of the European leader in the temperature sensor and closing mechanism markets.

The Group believes in the vertically integrated production process. Indeed, many manufacturing operations within

66CASE STUDIES

the material flow are performed in-house. It is also a very innovative company with seven R&D departments which currently employ more than 250 experts entirely dedicated to innovation and product enhancement. Moreover, most of the company assembly lines are semi-automatic or fully au-tomatic. This advanced technology allows them to provide flexibility within the production structure.

Description of Termogamma SAvER solution

SAvER (System for Available Energy Recovery) is an in-dispensable system for improving energy efficiency and reducing emissions in today's fast paced energy sources. SAvER delivers completely free energy to the user, recov-ering already existing energy. SAvER recovers waste heat from industrial processes and other thermal energy flows. PLUG&PLAY, transportable and tailored to the costumers’ actual needs and requirements.

SAvER can be applied at the bottom of processes using heat to recover the residual energy. It can deliver either hot water/air, chilled water/air or even electricity. The most common sources of waste heat suitable for cost-effective heat recovery are: ventilation systems extract, boiler and furnaces flue gases, air compressors, etc.

The heat contained in the exhaust gases of an industrial

67CASE STUDIES

furnace are a perfect source of FREE HEAT. Depending on the “quality” (the temperature) and the “quantity” (the flow) of this heat, the installation of a SAvER system may deliver different useful energies:

` Direct use of hot air for air inlet to burner pre-heating,

` Transformation into hot water to be used in heating and/or ACS applications,

` Steam production,

` Chilled water production (through absorption chillers),

` Electricity production (only possible with high quality waste heat).

Short description of Termogamma installation in Switzerland

To produce electromechanical components, the industrial process of this Swiss company utilizes various furnaces to melt aluminium which realise gases into the atmosphere at around 400 °C. Each furnace operates at full capacity h24 five days per week and at a lower mode two days per week. The technical analysis and the business plan developed by Termogamma have shown that the installation of two SAvER systems would have improved the efficiency of the factory using the recovered hot water with an estimated payback for less than 3.5 years. The customer believes in

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the Termogamma solution and has installed the two SAvER systems in February 2018. Each SAvER is able to generate for free 100kW of thermal energy as hot water which is used mainly in winter.

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Third SAvER system

After the installation of the two SAvER systems at the factory, the Swiss local Authority responsible for energy efficiency in the region has evaluated and approved the effectiveness of the systems, even avoiding the state energy financial aid due to the very short payback period of the installed plants. The company is very satisfied with the results obtained and it has recently ordered a new SAvER system which will be implemented by Termogamma in the coming weeks.

70CONTACTS


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