storage Fluch [Kompatibilitätsmodus] · TEM Food and Drink Industry, 26th of March 2012 Storage technologies –state of the art (1) Sensible fluid storages Sensible heat stored

TEM Food and Drink Industry, 26th of March 2012

Jürgen FluchAEE – Institut for Sustainable Technologies (AEE INTEC)A-8200 Gleisdorf, Feldgasse 19AUSTRIA

Intelligent storage concepts in the industry


Overview

� Storage technologies – state of the art

� Design of storages

� Available algorithms

� Algorithms used in tools

� Storages in the brewery industry – case studies

� Outlook

� Technologies and concepts for optimised design and

implementation in processes

� Roadmap Masterplan

� Storage Optimisation Concepts

� Challenges


Storage technologies – state of the art (1)

� Sensible fluid storages

� Sensible heat stored in fluid mediums as

• water, pressurised water, thermal oil, liquid brine

� Long-term experiences in several industry sectors

� Sensible steam accumulator

� Sensible heat stored in pressurised water including phase

changes while charging and discharging

� Experiences available but limited use due to requirements

of pressure vessels



� Sensible heat stored in solid storages

� Solid medium with integrated heat transfer

� Medium: concretes

� Practical testing but limited use

� Latent heat storages - PCM

� Isothermal storage in medium changing phases while

charging and discharging

� Medium: technical salts

� Tests in lab-scale, almost no experience in industry



� Long term use of sensible heat storages (esp. water

storages) in different industry sectors

� Challenges

� Bad storage management (control, integration of processes,

charging and discharging)

� No optimised integration and combination of processes in storages

(different temperatur levels, operating hours)

� No optimised design of storages (discharging, insulation, heat

losses, connections)

� Use of existing storages (no optimised capacity, relation of

dimensions, no optimised adaptions)


Design of storages included in Pinch analysis (1)

� Realisation of the existing improvement potential

on thermal energy in industry (Schnitzer et al,

2007 / Brunner et al, 2008)

� Demand site reduction via 3 step approach

• Technological optimisation (measure to enhance

energy efficiency)

• System optimisation (Pinch Analysis of a total

production site)

• Integration of renewable energy (based on exergetic

considerations)



� Curves

� Generation of the Hot Composite Curve

� Generation of the Cold Composite Curve

� Generation of the Grand Composite Curve

� Pinch point

� Generation of a heat exchanger network

� Consideration of all hot and cold streams

� Design of the heat exchanger network



� Batch processes – algorithms without storage consideration

� TAM – time average method proposed for batch processes applying the same procedure as for continuous processes (Linhoff et al, 1988)

� Time slice model for HEN and batch heat integration (Linhoff, Kemp, Pourali)

• in each time interval targets for hot and cold utility consumption are identified over the problem table algorithm

• all utility targets added to find the minimum utility during the batch period

• only direct heat exchangers in time intervals can be identified �� need for scheduling

� Scheduling (Adonyi et al, 2003)

• Search for a schedule that requires minimal external energy



� Batch processes – algorithms with storage

consideration

� Time dependent heat cascade analysis (Kemp, McDonald,

Zhao)

� Minimum units targeting based on time dependant heat

cascade analysis (Foo et al, 2008)

� Permutation method (Stoltze et al)

� Rematching (Zhao et al, 1998)

� Storage pinch approach (Krummenacher and Favrat, 2001)

� …


Storages in heat exchanger networks (1)

� EINSTEIN

� HEN algorithm for processes that are variable in time � selection of

matches is done based on an algorithm, partly drawn from the pinch

algorithm suggested by Kemp et al

� Heat exchangers are really simulated taking into account their true

operational schedules leading to slightly too low or high mass%

• Set a initial ∆ Cp

• Select hot stream with highest heat capacity flowrate Cp

• Run through all cold streams (loop)

- Calculate heat capacity flowrate Cp of each cold stream

- Check whether difference in Cp is smaller than allowable difference

- Calculate the temperature range in which hot and cold stream overlap

- The maximum transferable power is calculated between the hot and

cold streams

- The loop re-starts for the next cold stream

• Check for further availability of the hot stream

• Calculation stops when all cold streams are matched



� PE² - Combinatorial approach to

design HEN for batch processes

� Main steps use three criteria

• Power of heat exchanger

• Transferable energy –

if necessary over storage

• Exergy

� Definition of the combination of different

streams within the system in order to

design the heat exchanger network

� The weight of these criteria runs from

0-100. The best ranked heat exchanger

network (based on its energy saving

potential) is finally chosen



� Storage consideration

� Adapted time slice model

• calculate energy transferred

over a heat exchanger for

non- continuously processes

� Storage calculations

• limited to hot buffers

• integral part of the heat exchanger network design to calculate

the transferable energy

� Example: 2 hypothetical streams A (waste heat) and B (energy

demand)

• Calculation of available hot energy and necessary heating

demand �� heat surplus, energy demand, accumulated energy

• Maximum amount of storageable heat converted to a tank



� Heat exchanger design algorithms

including storages

� Continuous processes

� Batch processes

� Integration of solar thermal as a batch

� Algorithm tested

� Food industry: breweries, dairy

� Metal surface treatment industry

� Tools

� PE²

� EINSTEIN

� SOCO


� Data collection and energy and mass

balances

� Pinch analysis

� Heat exchanger network / storages

Storage concepts in the brewery industry

W85 tank

0

500

1000

1500

2000

2500

3000

28.03.201000:00

02.04.201000:00

07.04.201000:00

12.04.201000:00

17.04.201000:00

22.04.201000:00

27.04.201000:00

02.05.201000:00

07.05.201000:00

Time

Leve

l [hl

]

40

45

50

55

60

65

70

75

80

85

90

T [°

C]

W85 tank level W85 tank temperature

Brauwasser-Tank1

85°C

150m³

Brauwasser-Tank2

85°C

150m³

WürzekühlungBrauwasser, 1990m³

85°C

MaischenLäuternCIP SH

KH Res70 90°C

Vewerfleitungen SHHeißwasser Rückgewinnung aus Brüdenkondensation

(Ankochen/Entspannen)

Kondensatübertemperatur SH

FLAHA/KEG WW

CIP Filtration

Verfügbare SpeicherGesamt ~ 80 m³SOLL T = 65°C

CIP Heißwasser Für Filtration

Heißwasser fürFlasche/KEG

Abwasser KEG

KondensatübertemperaturKEG Halle

AbwärmeKältemaschinen

Übertrag BW in KH Reserve

Brüdenkondensat


Water storages in the brewery industry


Energy storage in the brewery industry (1)


Energy storage in the brewery industry (2)

-12.000

-8.000

-4.000

0

4.000

8.000

12.000

16.000

20.000

03.08. 00:00 04.08. 00:00 05.08. 00:00 06.08. 00:00 07.08. 00:00 08.08. 00:00 09.08. 00:00 10.08. 00:00 11.08. 00:00

Date/Time

Kum

ulie

rte

Ene

rgie

[MJ]

-4.500

-3.000

-1.500

0

1.500

3.000

4.500

6.000

7.500

Wär

mel

eist

ung

[kW

]

Kumulierte Energie (IN - OUT) Wärmeleistung Balancing (IN - OUT)

Cum

ula

ted e

nerg

y [

MW

h]

Therm

al capacity [

kW

]


Storage concepts – technologies useable

� Use of sensible storages in all sectors of the

industry with heating demand under consideration

of useful basic conditions

� Breweries

� Metal surface treatment industry

� Food industry

� Sorption heat storage

� Waste heat of block type thermal power stations

• Bakeries, dairies, fruit and vegetable industry

� Storage of waste use for use in batch processes

• Bakeries, metal treatment

� Storage of waste heat from campaign operation

• Fruit and vegetable industry


Storage concepts - strategies

� Austrian Masterplan for storages

� Buildings (AEE INTEC)

� Mobility

� Smart grids

� Industry (AEE INTEC)

� Roadmap for

� Development of technologies

� Development of strategies

� Involvement of international specialists

� Consulting the Austrian government and the European

Commission


Storage concepts - tools

� SOCO – Storage Optimisation Concept

� Development of a software tool

• Based on a pinch analysis and measured data of installed

storages in industry, district heating networks and trade

the following targets should be achieved using the SOCO

tool:

- Design of a heat exchanger network for changing load

profiles

- Design of a storage system taking the HEN into account

- Reduction of the energy demand by increasing the efficiency

- Integration of renewable energies esp. solar thermal where

technical and economical criteria are full-filled

- Design of a holistic optimisation concept and energy saving

potentials in complex thermal energy systems

- Available for energy auditors, managers, solar designer and

plant engineering companies � industry, trade, district

heating networks with complex heating and cooling streams


Storage concepts - challenges

� Challenges

� Presentation of the potentials and economic efficiency

� Storage management

• Optimised integration of storages (one or more!) in

processes and heat exchanger networks

• Optimised combination of processes

�� Use of the pinch analysis

• Charging and discharging

� Design

• Technology

• Geometry

• Internal installations, insulation

• Temperature layering

� Combination with renewable energies (solar thermal)


Storage concepts - outlook

� Targets

� Optimised integration of storages in the production

� Optimised combination of processes at comparable

temperature levels of supplying and demanding processes

� Reduction of energy (primary) consumption

� Increase of efficiency

� Reduction of costs


Intelligent storage concepts in the industry

Jürgen Fluch

[email protected] – Institut for Sustainable Technologies (AEE INTEC)A-8200 Gleisdorf, Feldgasse 19AUSTRIA

Documents

storage Fluch [Kompatibilitätsmodus] · TEM Food and Drink Industry, 26th of March 2012 Storage technologies –state of the art (1) Sensible fluid storages Sensible heat stored