Aeinnova

LIFE - HEAT-R

Welcome

AEInnova at Oil & Gas Conference

AEInnova has been participate in the Oil & Gas Conference, an event aimed at promoting intersectoral relations, as well as networking between the different actors and “key players”.

In there we presented our technology as well as the our Heat-R Life project. With nearly 300 attendees we could contact with 9 important people related to the Oil&Gas sector, our primary target.

 

 

GPEX/Gastech fair

Global Power & Energy Exhibition (GPEX) – co-located with Gastech – is the world’s leading gas and LNG showcase, the better place to find the latest strategies and technologies needed to adapt to the energy transition. The firts edition was developed in Barcelona and we had the pleasure of having a small stand there.

Our experience has been really positive counting 672 flyers, 76 contacts, 18 face-to-face meetings. Amazing!

 

AEInnova at Climate Change Mitigation in Energy Intensive Industries event

Our president, Dr. Raúl Aragonés, and our CEO, David Comellas, have attended the LIFE platform meeting on climate change mitigation in energy intensive industries in Utrecht, the Netherlands (26-27 September 2018).

The meeting is hosted by LIFE OPTIMELT (http://lifeoptimelt.com/announcement.htm), a project that is recovering waste heat in glass manufacturing, and is organised in cooperation with the Executive Agency for Small and Medium-sized Enterprises (EASME) and the European Commission’s Directorate-General for Climate Action (DG CLIMA).

The two-day gathering included plenary sessions on the policy context, industry commitments and technological solutions; workshops; a poster session; and field visits to the OPTIMELT project at the Libbey Leerdam glassware factory and Tata Steel’s Horizon 2020 project, HIsarna, both in the Netherlands.

 

Familia Torres winery: Prototype Design

A Heat-R energy recovery station will be installed in a configuration of 3 WHRU modules, 2 with heat column system and a larger one with heat pipes.

The first system will consist of 4 40×40 thermoelectric cells and one fan and the second, consisting of 6 40×40 thermoelectric cells and 2 fans.

According to the result of the thermographic analysis, it is established that the combustion gas duct of the biomass boiler is the favorable point for the placement of WHRU units. For reasons of ease of installation, WHRU units will be located at the top of the rectangular flue gas outlet duct at its exit from the cyclone and before the exit of the boiler building duct to the bag filter.

The working cycle of the biomass boiler is 24 hours and the flue gas outlet temperature varies between 250-300 ° C depending on the fuel used, which may be strains and branches and/or forest masses. The ambient temperature is between 35-45ºC.

In the mechanical part, the previous version of WHRU has been modified by natural convection to forced convection to obtain greater performance. Said cooling system consists of heat pipes and fans. These heatsinks are entirely copper, so a protective paint against corrosion will be applied.

The fans will operate by PWM control in order to maximize the thermal differential to obtain greater performance in the thermoelectric cells.

The WHRU modules will penetrate the duct with aluminum heatsinks, so make a cut in the duct to accommodate the recovery station.

Each of the modules will have an integrated sensor to be able to measure the temperature of the hot and cold face of the cells; and a current sensor to measure the power generated. Said sensor refers to the name of nodes.  4 sensors are going to be installed:

• Node 1: 3 temperature sensors (cold face, hot face, gases)
• Node 2: 3 temperature sensors (cold face, hot face, gases)
• Node 3: 4 temperature sensors (cold face, hot face, two gases)
• Node 4 (output): Power generated

Mechanical design

According to the visit to the facilities of Bodegas Torres the following are data taken:

Section 1:
• Rectangular duct with a useful area of 570x950x580x4
• Undercover
– Gas temperature circulating inside the duct: 250ºC
– Flow rate: 1 m / s
– Ambient temperature: 32.9ºC

Due to the number of modules to be installed, it will not be necessary to remove the entire conduit, a cut will simply be made in the upper part of the conduit and a housing with our generation devices will be housed.

The solution adopted, the flat housing, will allow us to install three WHRUs. This component has a configuration in the form of “Sandwich” since it is formed by three pieces. Base housing, Insulator, Handle and Insulating support.

4 cells WHRU Module

This device is a forced air cooling system, where fan revolutions are controlled by a PWM system to maximize the thermal differential generator in the peltier cell.
The fan speed regulation will be controlled by the information provided by PT1000 sensors connected to an electronic board that governs all these operations.

 

This WHRU module consists mainly of the following components:
1. 90x90x70 aluminum sensor. With a normal anodizing to improve corrosion resistance.
2. Maco-Support cells – Mica Insulator. This component will act as a fixation to the mounting duct, and at the same time it will act as an insulator, since this material has 0.3 W / mK of thermal conductivity and will improve the performance of the equipment. In addition, it will serve to house the cells and refer them to their connections.
3. Power box support. Made of carbon steel. It will act as a support for the power box and will be placed on the Heat Pipe in order to prevent it from getting hot.
4. Heat Pipe Column. Cooling system with an operating principle similar to thermosiphon. Its objective is to transport heat from the hot zone to the cooling zone from a high pressure fluid, which in this case are the fins. It is made of copper and covered by an oxidation protection paint.
5. NOCTUA F12 fan. Industrial fan made of polyamide, and with IP67 environmental protection. Responsible for cooling the heat transported by the Heat Pipe and cooling the component.
6. Electronic box. Inside will go the electronic sensing, electronic regulation. The cells will enter directly. It is made of aluminum and is black.
7. Cells. The installation of 4 cells, model TGM-287-1,0-1,3 of Kryotherm with dimensions 40x40x3.6 mm that can produce up to 6.9 W. is decided.

In total, 2 modules of this type will be installed.

6 cells WHRU Module

This device also has a forced air cooling system, just like the 4-cell model. It will have two fans instead of one and also regulated by an electronics.

This WHRU, being more robust, houses the central box of the power electronics.
This WHRU module consists mainly of the following components:
1. 280x120x60 aluminum sensor. With a black anodized to improve corrosion resistance.
2. Maco-Support cells – Teflon Insulator. This component will act as fixation of the cells, and at the same time will act as an insulator, since this material has 0.25 W / mK of thermal conductivity and will improve the performance of the equipment.
3. Duct support frame. Stainless steel, its function is the fixation to the conduit.
4. Power box support. Made of carbon steel. It will act as a support for the power box and will be located at the bottom of the device.
5. Heat Pipe. Cooling system with an operating principle similar to thermosiphon. Its objective is to transport heat from the hot zone to the cooling zone from a high pressure fluid, which in this case are the fins. It is made of copper with aluminum and covered by an oxidation protection paint. It has 12 cooling tubes.
6. NOCTUA F12 fan. Two industrial fans made of polyamide, and with IP67 environmental protection. Responsible for cooling the heat transported by the Heat Pipe and cooling the component.
7. Central power box. Inside will go all the electronics that will manage the 3 generation modules.
8. Electronic box. Inside will go the electronic sensing, electronic regulation. The cells will enter directly. It is made of aluminum and is black.
9. Cells. The installation of 4 cells, model TGM-287-1,0-1,3 of Kryotherm with dimensions 40x40x3.6 mm that can produce up to 6.9 W. is decided.
In total 1 module will be installed.

Electronics design

The electronics consist of 2 parts: power electronics and sensorization.
The power electronics collect the voltage of each channel (the electronics are made up of 7 channels), and join the powers into a single output at 14V.
The sensorization electronics have three functions:

  1. Monitor the temperature of the hot face, and the cold face of the modules.
  2. Check the fans used to cool the temperature of the Heat pipe. The speed of the fans should not be constant since it may be an unnecessary consumption, it is also interesting to prevent the cooling of the cold face from dragging (cooling) the hot face. For the 4-cell modules there must be 1 fan, and for the 6-cell module, 2 will be controlled.
  3. Monitor the temperature of the chimney gases with a PT100 sensor in the small modules, and with 2 PT100 sensors for the large module.

Power electronics

The power electronics of this project are composed of two elements: the DC / DC converter and the variable resistance, to adapt the load to the generated power.
DC / DC converter

The power electronics of this project has some important evolution of our previous electronics:
– We can control up to 7 channels simultaneously, in this way with a single power board the entire system is controlled.
– For the control, we have changed our previous SoC. The main advantage of this new SoC is that it allows to increase the Duty Cycle of the PWM in steps of 0.1%
– Another change is the MOSFET transistors used (IPT004N03L) with a an internal resistance of less than 0.6mΩ with a door voltage of 3.3V.
The software has been modified to prevent the voltage of the cells from falling below ~ 4V. If the Dutty-Cycle of the PWM is greatly augmented, the voltage of the cells drops, causing the cells to work very far from their optimum zone.
The following images show the block diagram used:

Variable resistance

The variable resistor is a voltage divider composed of a fixed value resistor and a variable ohm resistor based on a MOSFET transistor, as shown in the following figure.

HEAT-R Variable Resistance
The variable resistance consists of two MOSFETs, connected to a control and measurement system. The function is to take current and voltage readings, power calculation, and send them via Bluetooth to the Gateway.
The control system by reading at the input of the variable resistor, offers a voltage at the output of the microcontroller to regulate the MosFETs in order to adjust the ohmic value of these, going down from the 14V output of the DCDC convertor to 13,65V, in order to obtain maximum power at the converter output.

Below, the block diagram of the full system:

HEAT-R Variable Resistance Blocks

 

Sensorization

One of the requirements of the project is the integration of temperature and current sensors in order to know the operation of the 3 modules.

Temperature

It is an electronic module located in each WHRU, it has the function of obtaining the measurements of the cold face and hot face temperature of the Peltier Cell and the gas temperature. We will use a PT100 sensors and the system will control the fan power.

HEAT-R Temperature Sensor Blocks

 

Current

The meter consists of a HALL sensor plus the signal conditioner based on an integrated differential amplifier. The whole will be powered at 5V

 

Communication platform

The communications solution consists of nodes with sensors and gateway. The nodes will read the sensor data and using bluetooth technology they will communicate with the gateway. The gateway will act as a gateway receiving the data and sending it to the DAEVIS monitoring software.

 

Distiller Chemical Industry: Prototype Design

Location

The building of the boiler room where the chimney is located has a height of approximately 12 m. The chimney can be accessed by a cat ladder, but the floor next to the chimney must be considered as not practicable as part of the ceiling of the boiler room.

 

Design decisions

It is proposed to install 2 WHRU modules that will penetrate one of the WOGA boiler gas outlet chimneys.

The WHRU units will be installed one on each side of the chimney 600 mm wide.

WHRU modules will be equipped with waterblocks for water cooling.

The cooling water distribution installation will be provided with traps to avoid the presence of air in the water circuit.

Each WHRU unit will consist of 6 waterblocks. Each waterblock will cool the cold face of 6 peltier cells. Therefore, each WHRU unit will consist of 36 peltier cells (6 waterblock x 6 peltier cells).

To maximize the effect of temperature on the WHRU collectors, a deflector will be installed inside the rectangular chimney.

For monitoring the correct functioning of the prototype, 3 types of sensor nodes will be installed:

Type 1-Temperature Node: Th, Tc and Tgases output.

Type 2-Node Wattmeter to measure the power generated by the system. Said node will be installed inside the electrical panel.

2 units will be installed. of type 1 sensor nodes (one for each WHRU module) and 1 unit of type 2 node.

A LoRa Gateway will be installed to collect all the data sent by the sensors. The Gateway will be installed inside the boiler room right next to the existing electrical panels. The Gateway will be powered from one of the existing boxes.

 

Gomà Camps Paper Industry: Technical Visit

In order to start a thermoelectricity project, it is important to have a physical visit to the facilities in order to determine the waste heat ranges and the temperature in addition to the installation of the WHRU system.  The technical visit was made at the Gomà-Camps facility in La Riba (Tarragona) on July 9th, 2018.

 

Heat Source

In the paper industry, machines for drying tissue paper are provided with a hood that blows hot air at high speed against tissue paper, and a rotary dryer cylinder called Yankee partially covered by said hood. Tissue paper dries thanks to the combination of the drying cylinder that transmits heat by contact from the superheated steam that circulates inside and the hood that dries by heat and mass transfer.

 

The heat transmitted by the dryer cylinder is not enough to dry the paper. For this reason, the hood that injects air at about 450ºC over the cylinder is used.

The hood is divided into two parts, called respectively wet part and dry part.

In operation, the wet tissue band enters the dryer machine adhering on the surface of the Yankee cylinder for drying, in turn the hot air flows through the hood until it is applied against the cylinder to come into contact with the wet tissue band . In this way, as the cylinder rotates, the tissue band dries, passing first under the wet part of the hood and then under the dry part of the hood.

Each part of the hood has its own air circuit, so that each circuit comprises a motorized fan that blows air, which is heated by means of heating means before entering the corresponding part of the hood.

The hood extracts evaporated water from the paper. This vapor is concentrated in the circulating air so a quantity of air must be purged outside. To compensate for it, fresh air must enter from outside. The hood respectively includes an air supply inlet for the wet part and an air supply inlet for the dry part. The part of the hood on the Yankee cylinder comprises on its outer surface a plurality of openings that communicate with the inside of the hood. Some openings give way to blown air and others recover moist air.

From both parts of the hood, wet and dry, a portion of air, the exhausted one, is extracted in order to maintain a humidity of 55%.

In GOMÀ-CAMPS tissue paper manufacturing facilities in La Riba there are two machines for drying tissue paper: drying machine No. 5 and drying machine No. 6.

Measurements in drying machine No. 5

In the drying machine nº 5, 3 points were analyzed:

Point 1
Point 2
Point 3

Measurements in drying machine No. 6

In the drying machine nº 6, 5 points were analyzed:

Point 1
Point 2
Point 3
Point 4
Point 5

 

Conclusion

After analyzing all the data obtained and the physical spaces, the most appropriate points for the installation of WHRU units are:
1) Piping of the combustion gases of the drying machines nº5 and nº6: the starting temperature of the combustion gases would be around 200-220 ° C.
2) Hot air pipe to the hoods (dryer hood).

This option number 2) was posed to the meeting but it would be an option to discard because the pipe where the WHRU unit would be installed does not respond to the requirement of being a pipe with residual heat.
Therefore, the installation of the WHRU prototype is proposed in one of the gas pipes of the exit of the drying machines. For cooling the WHRU, water can be available at 14-20 ºC.

 

 

Nit de l’Eficiència: EmErgEnt prizes

Aeinnova finalist in The Night of the Efficiency

The Cluster of Efficient Energy of Catalonia (CEEC) organizes, annually, the Night of the Efficiency, an event that has become the meeting point for the main agents in the sector.

Aeinnova, an active member of the CEEC, had the honor of being a finalist in the Emergent awards aimed at rewarding the best start-ups in the field of energy efficiency.

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Aeinnova, an active member of the CEEC, had the honor of being a finalist in the Emergent awards aimed at rewarding the best start-ups in the field of energy efficiency.


 

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Industry 4.0 & IIoT: Perspectives, challenges & experiences

Aeinnova at the Industry 4.0 & IIoT conference: Perspectives, challenges & experiences


Aeinnova has been invited to participate in the Industry 4.0 & IIoT conference: Perspectives, challenges & experiences organized by Orbital 4.0 within the framework of the Industry 4th promotion of the Terrassa City Council.

In addition to Aeinnova, they participated in the Vodafone conference, presenting their communications technology NB-IoT and Esbelt as a company where Industry 4,0 innovation project has been implemented.

The global participation was around 25 people and there was a local impact on the media so we value our participation as very positive.

 

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