Aeinnova

LIFE - HEAT-R

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Keraben Ceramics 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 Keraben (Castellón) on Dec 9th, 2019.

Heat Source

Thermographic measurements have been made in the the furnace zone. The points analyzed are shown below:

Measurements

Below you can see the results obtained

 

Name Average Min Max Emissivity Standard Deviation
Furnace outlet 106,8 °C 39,2 °C 254,2°C 0,98 51,69ºC

Conclusion

The flue gas outlet chimney from the porcelain tile firing furnace has been identified as a potential heat recovery point for the installation of WHRU units.

The furnace has a length of 111.3 m and a total of 160 burners. The outlet temperature of the gases is approximately 210-230ºC.

The installation of WHRU units by contact with the surface of the pipe and which eliminate heat by natural convection (sink) will be considered, as there is no availability of water. The surface temperature of the pipe would be around 160-180ºC.

The plant has compressed air that could be considered to help cooling.

Celsa Steel 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 Celsa (Castellbisbal, Barcelona) on May 11, 2018.

Heat Source

Thermographic measurements have been made in the the furnace zone, the casting area and in the beam blank.. The points analyzed are shown below:

Measurements

Below you can see the results obtained

Beam blank - Load Zone

 

Name Average Min Max Emissivity Standard Deviation
Load zone 393,9 °C 74,5 °C 653,4°C 0,98 237,38ºC
Beam blank - Out

Name Average Min Max Emissivity Standard Deviation
Out 182,2°C 39,6°C 645,8°C 0,98 175,74ºC
Beam Blank - Linear Out

Name Average Min Max Emissivity Standard Deviation
Linear Out 188,4°C 43,9°C 619,2°C 0,98 191,36ºC
Smelting Furnace

Name Average Min Max Emissivity Standard Deviation
Smelting Furnace 143,1°C 46,0°C 812,0°C 0,98 114,76ºC
Smelting Area

Name Average Min Max Emissivity Standard Deviation
Smelting Area 15,9°C 0,2°C 422,8°C 0,98 14,17ºC
Bucket emptying area

Name Average Min Max Emissivity Standard Deviation
Bucket emptying area 85,5°C 14,3°C 530,4°C 0,98 – ºC

Conclusion

After the visit to CELSA S.A, we have identified different potential heat recovery points, all of them at high temperatures (above 500ºC).

To carry out the first pilot, special interest has been paid in the output of the beam blank. In this outlet, there are groups of 6 transmission rollers that allow up to a total of 6 metal beams to be distributed to a collector clamp at a time.

Once the beams reach the entire length, a bridge crane lifts the beam from its towing and resting area to a front area, where it is again dragged by another transmission system to an outside area, where it is transported to a cooling area.

In order to make a schedule to establish the performance of the equipment, the best case and worst case of the duration of the beam blank will be analyzed in the final drag zone, and the time it takes to replenish a new beam blank. This calculation will allow us to analyze the maximum and minimum performance cycles of the equipment as well as on a next visit, the maximum power that can be generated per hour. So that:

– The time that the beam remains in the unloading zone, and runs through column 2:
Worst case: 29 seconds, Best Case: 62 seconds.

– The replacement time between beam and beam:
Worst case: 64 seconds. Best case: 19 seconds.

The time in which the beam blank goes from the shock column on the right to the one on the left is 10 seconds. This means an additional 10 second stay of the beam blank in the exposure area (and electrical generation).

After analyzing the times, we consider it appropriate to choose the limit column on the left to mount the possible pilot, as additional exposure is achieved.

Cementos Molins Cement 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 Cementos Molins (St. Vicenç del Horts, Barcelona) on Juny 29th, 2018.

Heat Source

In Cementos Molins there is a big variety of heat points. The points analyzed are shown below:

Measurements

Below you can see the results obtained

Rotary Oven Hopper

 

Name Average Min Max Emissivity Standard Deviation
Rotary Oven Hopper 186,84°C 93,00°C 276,38°C 0,98 37,76ºC
Rotary Oven Point 1

Name Average Min Max Emissivity Standard Deviation
Rotary Oven Point 1 368,86°C 58,13°C 398,59°C 0,98 36,14ºC
Rotary Oven Point 2

Name Average Min Max Emissivity Standard Deviation
Rotary Oven Point 2 367,08°C 343,46°C 388,50°C 0,98 9,57ºC
Pipe WOGA oil boil point 1

Name Average Min Max Emissivity Standard Deviation
WOGA oil boil point 1 175,17°C 33,77°C 362,51°C 0,98 80,92ºC
Rotary Oven Chimney

Name Average Min Max Emissivity Standard Deviation
Rotary Oven Chimney 18,43°C -6,00°C 62,53°C 0,98 15,34ºC
Industrial processing 1

Name Average Min Max Emissivity Standard Deviation
Industrial processing 1 127,85°C 35,52°C 799,40°C 0,98 122,47 ºC
Industrial processing 2

 

Name Average Min Max Emissivity Standard Deviation
Industrial processing 2 132,45°C 18,25°C 838,23°C 0,98 148,06ºC
Gas outlet chimney

Name Average Min Max Emissivity Standard Deviation
Gas outlet chimney 34,49°C -3,06°C 93,19°C 0,98 21,17ºC

 

Heating pipe

 

Name Average Min Max Emissivity Standard Deviation
Heating pipe 27,69°C -5,67°C 127,933°C 0,98 16,94ºC

 

 

Conclusion

After the visit to CIMENTS MOLINS, different potential heat recovery points have been identified, although not all of them are suitable.

Most pipes in the installation have an inner ring of refractory material having to withstand very high temperatures.

There are some pipes in the installation without refractory material inside that conduct gases at about 300ºC. The identified pipes are heat insulated and have a non-commercial diameter (greater than the standardized pipe diameter). This fact, together with the high height of these pipes, makes it impossible to place WHRU modules, from the point of view of their installation.

The manufacturing process of calcium aluminate cement (molten) is another point to consider the installation of WHRU units.

The installation of WHRU modules at this point is not suitable for several reasons:
• Dirty environment (with dust and vapors) and corrosive.
• Very high ambient temperature.

 

Another point to consider the installation of WHRU modules is in the rotary oven.

The rotary oven has an internal temperature of 1000 ºC. For this reason, the furnace is covered with refractory material that causes the outer temperature of the furnace surface to be around 390 ° C.
On the other hand, the available area existing at one end of the rotary kiln together with the ease of bringing cooling water to this point, makes it possible to consider the placement of WHRU modules that take advantage, by radiation, of the heat that emerges from the surface of the rotary oven.

The cooling water would come from the cooling towers. Said water leaves at about 25 ° C from the cooling towers. In the rotary oven, the cooling water is used to cool the rollers that move the oven. Very close to the area proposed for the installation of the WHRU modules, there is a roller and, consequently, availability of cooling water.

The Head of Engineering and Maintenance informs us that he would send us the cooling water to the WHRU installation point and return it to cooling towers through the return water network at his exit from the waterblocks.

Therefore, it is established that the installation of WHRU modules for the use of residual heat by radiation from the surface of the rotary oven would be the prototype to be proposed in this installation.

 

Gomà Camps Paper Industry: Prototype Implementation

Mechanical

Electrical

Electrical panel with its respective electrical safety: two 16A fuses at the input of the inverter, a 10A magneto thermal switch that cuts the phase and the neutral.

Electronics

DC-DC converter

Features

Minimum Input Open-circuit voltage for turn-on 4V
Maximum Input Open-circuit voltage for turn-on 24V
Maximum Input Peak-Peak Voltage Ripple N/A
Maximum Output Peak-Peak Voltage Ripple ±0.4V
Switching Frequency 50kHz
Efficiency >85%
Max Input Current 3.5A per canal
Max output Voltage 15V

 

Communications

AEInnova participates in the Day of Reflection and Debate organized by the Chair of Leadership and Democratic Governance of ESADE

Day of Reflection and Debate organized by the Chair of Leaderships and Democratic Governance of ESADE

On September 30, the World Day of Reflection and Debate was organized by the ESADE Chair of Leadership and Democratic Governance, led by Prof. Àngel Castiñeira. Under the motto Are we in time? Business leadership to transform the world the day focused on the 2030 agenda and the United Nations Sustainable Development Goals (SDG).

The event was attended by a number of important personalities from the business, social and political world of our country with a long list of top business executives and various political leaders led by the Honorable Àngels Chacón, Minister of Enterprise and Knowledge of the Generalitat de Catalunya.

Initially, several working groups were created that reflected on the different axes related to SDG’s. AEInnova participated in a group that reflected on energy where he could explain his experience in thermoelectricity, achieved from the European project LIFE HEAT-R, and share with other major companies and organizations the great challenges that we are faced with a real energy transition and, unfortunately, transcending the intentions of each company.

Next, a joint statement was made in which there were concerns about the threat of climate change and the need to redirect business activities towards sustainable development to meet the challenges of the 2030 agenda. Multiple proposals on experiences and testimonies were presented and commented on in multiple sectors that provided a comprehensive approach to the situation, concluding that it is necessary for companies and society to act in a firm, determined and courageous manner.

The Day of Reflection and Debate has an annual nature with the objective of reflecting, from a strategic perspective, on issues relevant to the public agenda and providing new ideas and approaches that will lead the development and progress of the country.

Inauguration of the 26th academic year of the Salesian University School of Sarria (EUSS)

On October 2, Dr. Raúl Aragonés gave the inaugural conference of the 26th academic year of the Salesian University School of Sarria (EUSS).

His conference began with a review of the most relevant milestones of Humanity and then focused on the progress that has taken place in the last 150 years and its severe environmental consequences.

In a second part, he reflected on the current energy model, which he defined as unfeasible, and then presented alternative technologies in energy generation.

Finally, he made a special mention to the Energy Harvesting technologies, explaining the status and progress of the European LIFE HEAT-R project that they are developing in AEInnova.

Dr. Raúl Aragonés is a EUSS graduate student and he was grateful for the honor to participate in this prestigious event at a university that was fundamental in his training.

 

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.

 

 

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.

 

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