Energy Systems, Process Integration and Solutions to Energy Issues in Industrial and Urban Systems for Energy Saving and Pollution Reduction

Currently, when designing finned heat exchangers (FHE), the average value of the entire heat transfer coefficient (HTC) is considered. However, each row of the heat exchanger (HEX) has different hydraulic-thermal characteristics. The novelty of this research is to present the differentiation of the individual air-side Nusselt number and Darcy-Weisbach friction factor correlations in each row of FHE using CFD modelling. FHE has four-rows, circular tubes, and continuous fins with a staggered tube arrangement. Relationships for the Nusselt number and D-W friction factor derived for the entire exchanger based on CFD modelling were compared with those available in the literature, determined using experimental data. The maximum relative differences between the Nusselt number for a four-row FHE determined experimentally and by CFD modelling are in the range from 22% for a Reynolds number based on a tube outside diameter of 1000 to 30% for a Reynolds number of 13,000. The maximum relative differences between the D-W friction factor for a four-row FHE determined experimentally and by CFD modelling are in the range of 50% for a Reynolds number based on a tube outer diameter of 1000 to 10% for a Reynolds number of 13,000. The CFD modelling performed shows that in the range of Reynolds numbers based on hydraulic diameters from 150 to 1400, the Nusselt number for the first row in a four-row FHE is about 22% to 15% higher than the average Nusselt number for the entire exchanger. In the range of Reynolds number changes based on hydraulic diameter from 2800 to 6000, the Nusselt numbers on the first and second rows of tubes are close to each other. Correlations of Nusselt numbers and D-W friction factors derived for individual tube rows can be used in the design of plate-fin and tube heat exchangers used in equipment such as air-source heat pumps, automotive radiators, air-conditioning systems, and in air hot-liquid coolers. In particular, the correlations can be used to select the optimum number of tube rows in the exchanger. Full article

Turbulences in energy prices have a major effect on the energy industry. These disturbances should allow more efficient operation and the optimisation of technologies, leading to more versatile operation with model-based methods. In our study, a coke oven gas purification system was examined. The system consists of three columns, which interact and are modelled in Aspen Plus. After identifying the steady-state model, sensitivity analyses were conducted to obtain more information on the effects of the parameters that can and cannot be influenced by operating circumstances. Finally, the model was used to carry out optimisation studies to find the most beneficial operating conditions under the gas composition requirements. Two optimisation strategies were examined. In the case when only the purity was concerned, 0.54 g/Nm³, 0.01 g/Nm³, and 0.03 g/Nm³ concentrations were found for H₂S, NH₃, and HCN, respectively. However, when the washing water temperature was included, the concentrations of H₂S, NH₃, and HCN increased to 1 g/Nm³, 0.5 g/Nm³, and 0.04 g/Nm³, still below the environmental regulations. However, the latter case will be more feasible energetically because it can be completed without using refrigeration and facilitates lower washing water streams. Full article

The conversion of biomass to olefin by employing gasification has recently gained the attention of the petrochemical sector, and syngas composition is a keystone during the evaluation of process design. Process simulation software is a preferred evaluation tool that employs stoichiometric and kinetic approaches. Despite the available literature, the estimation errors of these simulation methods have scarcely been contrasted. This study compares the errors of stoichiometric and kinetic models by simulating a downdraft steam gasifier in PRO/II. The quantitative examination identifies the model that best predicts the composition of products for the gasification of Japanese wood waste. The simulation adopts reaction mechanisms, flowsheet topology, reactions parameters, and component properties reported in the literature. The results of previous studies are used to validate the models in a comparison of the syngas composition and yield of products. The models are used to reproduce gasification at temperatures of 600∼900 °C and steam-to-biomass mass ratios of 0∼4. Both models reproduce experimental results more accurately for changes in the steam-to-biomass mass ratio than for temperature variations. The kinetic model is more accurate for predicting composition and yields, having global errors of 3.91%-mol/mol and 8.16%-g/g_BM, respectively, whereas the simple stoichiometric model has an error of 7.96%-mol/mol and 16.21%-g/g_BM. Full article

In this paper, driving strategy optimization for a track is proposed for an energy efficient battery electric vehicle dedicated to the Shell Eco-marathon. A measurement-based mathematical vehicle model was developed to simulate the behavior of the vehicle. The model contains complicated elements such as the vehicle’s cornering resistance and the efficiency field of the entire powertrain. The validation of the model was presented by using the collected telemetry data from the 2019 Shell Eco-marathon competition in London (UK). The evaluation of applicable powertrains was carried out before the driving strategy optimization. The optimal acceleration curve for each investigated powertrain was defined. Using the proper powertrain is a crucial part of energy efficiency, as the drive has the most significant energy demand among all components. Two tracks with different characteristics were analyzed to show the efficiency of the proposed optimization method. The optimization results are compared to the reference method from the literature. The results of this study provide an applicable vehicle modelling methodology with efficient optimization framework, which demonstrates 5.5% improvement in energy consumption compared to the reference optimization theory. Full article

The greenhouse gas emissions from the transportation sector are the primary cause of climate change. As a result, many studies have developed new powertrains with reduced CO₂ emissions for the automotive industry. The gas turbine cycle coupled to an alternator is an autonomy booster for series hybrid electric vehicles. Many gas turbine configurations are proposed in the literature to obtain the highest cycle efficiency. This paper suggests a new architecture offering higher efficiency than all the previous cycles. The two-step methodology consists at first of a sensibility analysis using VBA and Refprop to determine the optimal operating conditions in terms of higher efficiency. The selected cycle consists of two compression stages with an intercooler, a combustion chamber, a cooled hot pressure turbine, an uncooled low-pressure turbine, and a recuperator. The efficiency of this design reaches 51.39%, which approximately matches the designs compared in the literature, but is more compact because it does not require a second combustion chamber. Full article

This work presents the synthesis of heat-integrated water networks (HIWNs) by using mathematical programming. A new superstructure is synthesised by combining a water network and a modified heat exchanger network. Based on the proposed superstructure, a mixed-integer nonlinear programming (MINLP) model is developed. The model is solved by using a one-step solution strategy enabling different initialisations and the generation of multiple solutions, from which the best one is chosen. The results show that the proposed model can be effectively used for solving HIWN problems of different complexities, including large-scale problems. Full article

Condensation heat transfer characteristics (using R410A as the working fluid) were studied experimentally to evaluate the heat transfer performance in copper and stainless-steel heat transfer tubes (smooth and enhanced). Experiments were carried out for a mass flux that varied from 250 to 450 kg m⁻² s⁻¹, at a saturation temperature of 318 K. Single-phase heat balance verification found that the heat loss is less than 6%, and the deviation between single-phase experimental results and various prediction correlations is less than 15%. Additionally, tube side condensation flow patterns were observed and recorded. Experimental results found that the enhancement ratio of the condensation heat transfer coefficient (enhanced tube/smooth tube) of the three-dimensional surface (1EHT) tube is in the range of 1.15~1.90, while the ratio of the micro-fin (HX) tube is in the range of 1.18~1.80. Heat transfer performance is affected by material conductivity, with the thermal conductivity of the smooth tube slightly affecting the heat transfer performance; larger heat transfer enhancements are produced in the enhanced tubes. At a low mass flow rates and vapor qualities, the flow pattern is a stratified wavy flow, while at higher mass flow rates and vapor qualities, the flow pattern is an annular flow (with the area in the enhanced tube being larger than the area of a smooth tube). Flow patterns in the smooth tube are consistent with the predicted values shown in previously reported flow pattern maps. A flow pattern diagram for condensation heat transfer in enhanced tubes is presented as part of this study. The condensation heat transfer coefficient increases with an increase in mass flow. When the mass flow rate increases, the turbulence of the liquid flow increases and the liquid film becomes thinner; thermal resistance is reduced and the heat transfer coefficient increases. Heat transfer values at lower mass velocities increase slightly with increasing mass flux values; however, at higher mass flux rates the heat transfer increase is larger than that at low mass flux values. Finally, tubes produced from high thermal conductivity materials produce larger heat transfer performance gains than the gains found in smooth tubes; small diameter tubes produce larger gains than larger diameter tubes. Full article

Changing the fuel mix used in the heating industry, i.e., switching to greener fuels, is one of the possible solutions to prevent rising costs for final consumers in the context of rising emission allowance prices. This paper presents a methodology that offers the possibility to perform a comprehensive technical and economic assessment of a theoretical solution—changing the fuel mix of centralized heating sources—and other strategic decisions within a district’s heating systems. Emphasis is placed on fuels with a negative price, such as municipal waste. The presented approach can also be used to assess the effect of other significant changes related to the configuration of district heating systems on the economy of the plant, such as the impact of a decrease in heat demand and implementation of a steam turbine. The key benefit of this paper is an approach based on mathematical modelling of the operation of individual boilers with different operating parameters in terms of their start-up, shutdown, and mode of operation. A unique approach of optimizing an operation’s schedule using dynamic programming is presented, which enables the selection of a suitable solution for the configuration of binary variables in consecutive time steps. In this way, it is possible to achieve a more accurate estimate of the economics of the facility at the strategic planning stage that will consider the real operational capabilities of the heat source given its technical limitations. Using this approach, up to a 4% reduction in variable operating costs was achieved in the model case, when compared to static time interval planning. Full article

Industrial sectors are improving their energy efficiency and increasing their share of renewables for heating and cooling demands by using lower emission technologies. One specific approach to help achieve these targets is the integration of heat pumps (HPs) in industrial processes. However, due to the temporal variation of the heating and cooling requirements in non-continuous processes, the integration of HP is challenging. In this paper, a structured method for the design of HP integration is proposed. The method implements an engineer-centred workflow that extends the concept of the Indirect Source Sink Profile (ISSP) to HP integration. For this purpose, an adapted Grand Composite Curve is derived from the ISSP. This ensures correct HP integration across the pinch while maintaining the temperature lift of the HP small. The proposed workflow is applied to a demonstration case study and a case study from industry. In both cases, the resulting system with integrated HP enables the elimination of hot utility demand and significantly reduces cold utility demands. The static paybacks of the proposed solutions are in the range of 4.5 to 5 year. Full article

Economic criteria have prevailed in studies on integration of renewable energies. Tons of dangerous emissions are emitted by a biomass fuel, causing negative impacts over atmosphere and health. Current research proposes Pinch Analysis of solar thermal energy and the joint use of biomass (sugarcane bagasse) to produce heat and power in a Caribbean sugar mill; measuring emissions like: carbon oxide $CO,$ carbon dioxide $C{O}_2,$ dinitrogen monoxide $N_{2}O,$ nitrogen oxides $N{O}_x$, sulfur oxides $S{O}_x,$ non-methane volatile organic compounds NMVOC, methane $C{H}_4$, and particulate matters, to have a global and clear view of the impacts of biomass as a renewable fuel. Variables like kWh cost, the installation and device area of renewable energy, and greenhouse gas emissions, are analysed to assess the effect on the integration final design, the target of which is to control the use of biomass. It is possible to produce an economically competitive integration design of solar system $LCO{E}_{th solar}$ = 0.0636 USD/kWh, $LCO{E}_{ele}$ = 0.1392 USD/kWh), zero greenhouse gases emissions $(\Delta T_{minrew}=7 °\mathrm{C}$), and deletion of 378,711.53 t/year of $C{O}_2$ and 9567.56 t/year of solid particles. There are many possibilities that can implemented; in one of them, bagasse burning is reduced by 30% and the solar collector network for required power production is reduced by 68%. Full article

The purpose of the present study is to simulate the continuous bend erosion process in different directions, using the dense discrete particle model (DDPM). The influence of the length of the straight pipe in the middle of the continuous bend is investigated. The Rosin–Rammler method is introduced to define the diameter distribution of erosion particles, which is theoretically closer to the actual engineering erosion situation. The numerical model is based on the Euler–Lagrange method, in which the continuous phase and the particle phase are established on a fixed Euler grid. The Lagrange model is used to track the particles, and the interaction between particles is simulated by particle flow mechanics theory. The velocity field distribution, pressure variation, and turbulent kinetic energy of gas–solid two-phase flow, composed of natural gas and gravel in the pipeline, are studied. The simulation results, using the one-way coupled DPM and the four-way coupled DDPM, are compared and analyzed. The results show that the DDPM has good accuracy in predicting the distribution of the continuous bend erosion processes in different directions. The erosion rates of particles with an average distribution size of 50 μm are significantly increased (8.32 times), compared with that of 10 μm, at the same gas transmission rate. It is also indicated that it is important to consider the impact between particles and the coupling between fluid and particles in the erosion simulation of the continuous elbow when using the CFD method. Full article