11th IEA Heat Pump Conference 2014 ANNEX 35/13: Workshop on industrial heat pumps
How heat pumps can be used to improve energy efficiency of industrial processes M. Sc. Stefan Wolf, Dr. Ulrich Fahl, Prof. Dr. Alfred Voß Institute for Energy Economics and the Rational Use of Energy (IER), University of Stuttgart, 70565 Stuttgart, Germany
[email protected]
The European Union and especially Germany have set ambitious targets for the reduction of CO2 emissions. To meet these targets, the CO2-intensity of energy provision has to be reduced while energy efficiency has to be increased in all energy consuming sectors. The German industry accounts for 28 % of the country’s entire final energy demand and three fourth of this energy are needed for heat generation. Heat pump systems offer the opportunity to recover low temperature waste heat and thereby to reduce the overall energy usage of industrial processes. To determine the potential and to promote the application of heat pumps in the industry, the research project “Potential analysis for industrial heat pumps in Germany” had been launched. This project is part of the German contribution to the international research project ANNEX 35/13 “Application of industrial heat pumps”. The presentation will give a brief overview of the results of this project. At first a short introduction into the structure of the German industry and its energy demand will be given. This is followed by an overview of heat pump applications in a broad range of industrial branches. More specific information will be given for two very different application examples of process integrated heat pumps. In the first example, details of the development of a high temperature heat pump using the refrigerant R245fa will be presented. This heat pump is integrated into a cleaning system for metal parts. The second heat pump is integrated into a kilning plant. It uses a moist exhaust airflow to preheat the supply air.
University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
How heat pumps can be used to improve energy efficiency of industrial processes S. Wolf, U. Fahl, A. Voß Institute for Energy Economics and the Rational Use of Energy (IER)
11th IEA Heat Pump Conference IEA HPP/IETS Annex 35/13 Workshop 12th May 2014 in Montreal
University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Providers of industrial heat pumps in Germany Company
Description
Refrigerant
max. Temp.
Status
Combitherm [1]
High temperature heat pump R245fa
100 °C on the market
Emerson [2]
Single screw compressor
R717
90 °C on the market
GEA [3]
Double screw compressor
R717
90 °C on the market
HKT [4]
Demonstration plant
R600a
120 °C
R&D phase
Siemens [5]
Refrigerant laboratory test
LG-6
140 °C
R&D phase
Thermea [6]
High temperature heat pump
R744
90 °C on the market
[1] Klein, S.: Hochtemperatur-Wärmepumpen: Einsatzmöglichkeiten in der Industrie (WTT-Expo 2014). Karlsruhe, 13.04.2014 [2] Emerson Climate Technologies: Single Screw Ammonia Heat Pumps: Harness Your Heat… Don’t Reject It. Aachen, 2011 [3] Dietrich, W.; Fredrich, O.: GEA Grasso heat pumps using ammonia – the megawatt range (ACHEMA Kongress 2012). Frankfurt am Main, 13.06.2012 [4] Huber, K.: Prozesswärmepumpen - Medientemperaturen bis 110 °C (4. VDI-Fachkonferenz: Wärmepumpen 2013 - Umweltwärme effizient nutzen). Raunheim, 12.06.2013 [5] Reissner, F.; Gromoll, B.; Schäfer, J.; Danoc, V.; Karl, J.: Experimental performance evaluation of new safe and environmentally friendly working fluids for high temperature heat pumps (European Heat Pump Summit 2013). Nürnberg, 15.10.2013 [6] Glaser, F.: Energy efficiency and sustainability in production and building technology (European Heat Pump Summit 2013). Nürnberg, 16.10.2013
How heat pumps can be used to improve energy efficiency of industrial processes
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University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Selected applications of industrial heat pumps in Germany - Size Collection of 18 heat pump applications in the German industry: ●
13 use waste heat to provide space heating
●
5 use waste heat to provide process heat 10
number of heat pumps
9
total: 18
8 8
7 6 5 4 4
3
3
2 1
2 1
0 < 50 kW
50 to 100 kW 100 to 500 kW
500 kW to 1,000 kW
> 1,000 kW
heating capacity
How heat pumps can be used to improve energy efficiency of industrial processes
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University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Selected applications of industrial heat pumps in Germany - Temperatures Collection of 18 heat pump applications in the German industry: 13 use waste heat to provide space heating
●
5 use waste heat to provide process heat 100 90 80 70 60 50 40 30 20 10 0
82
80 70
70
60 45
50
40
42 28
18
18
25
25 15
55 no data available
temperature [°C]
●
60
65
65
68
60
50
50 50
27
35
30
20
35
21
How heat pumps can be used to improve energy efficiency of industrial processes
27
25
35
23
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University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Example 1: Part cleaning system Integration of a high temperature heat pump using R245fa into an industrial part cleaning system in cooperation with Dürr Ecoclean GmbH and Combitherm GmbH.
Source: Combitherm GmbH
Source: Combitherm GmbH
How heat pumps can be used to improve energy efficiency of industrial processes
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University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Example 1: Part cleaning system Data: reciprocating displacement compressor, 45 kW nominal heating capacity, 110 °C condensing temperature, pressure ratio 4,3, frequency converter speed control
How heat pumps can be used to improve energy efficiency of industrial processes
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University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Example 1: Part cleaning system ●
Bath preparation capacity increased by 75 %
●
Energy consumption reduced by 31 %
●
Under typical operating conditions the heat pump saves 24 t/(CO2*a) COP (W50/W100) 5 4
3,4
3,3
50
60
COP [-]
3,1
3,1
3 2 1 0 25
70
drive frequency of the compressor [Hz] How heat pumps can be used to improve energy efficiency of industrial processes
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University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Example 2: Malt production Electric compression heat pump in malt production Industrial branch
Food - malt production
Type of heat pump
Electric compression heat pump
Heating capacity
3,250 kW
Heat source description
Process exhaust air
Heat source temperature
23 °C
Heat sink description
Process heat for a kiln
Heat sink temperature
35 °C
COP
6,3
refrigerant
R717 (Ammonia)
Installation cost
1.820.000 € (Heat Pump & Installation)
Payback period
5,3 a
Internal return rate (IRR)
24 %
How heat pumps can be used to improve energy efficiency of industrial processes
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University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Example 2: Malt production
26 °C
10 °C
35 °C
85 °C
Source: based on Mönch, D.: Reduktion des Energieverbrauchs und der energiebedingten CO2-Emissionen bei der Herstellung von Malz durch den Einsatz einer Großwärmepumpe in Verbindung mit einem Blockheizkraftwerk: Demonstrationsvorhaben. Abschlussbericht. Hamburg, 2012
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University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Conclusion ●
Heat pumps can provide high temperatures up to 100 °C at large heating capacities (several MW).
●
Industrial heat pump systems in Germany reach payback times between 2 and 7 years (IRR between 12 % and 50 %)
●
Heat pumps become especially economical feasible, when both hot and cold side are used
Heat pumps are ready for the industry! Barriers and threats: ●
Insufficient knowledge about industrial processes among HVAC planners
●
Rising electricity prices in Germany, while gas prices remain stable.
How heat pumps can be used to improve energy efficiency of industrial processes
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University of Stuttgart Insitute for Energy Economics and the Rational Use of Energy
Partners and funding Informationszentrum Wärmepumpen und Kältetechnik e.V. (IZW) Funding:
●
Federal Ministry of Economics and Technology (BMWi)
●
EnBW Energie Baden-Württemberg AG
Project number: 0327514A
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