4art Cicle tècnic d'energia a la industria Jornada: Generació de calor per a usos industrials Ponència: Aprofitament de calor residual a la indústria Ponent: Oriol Gavaldà (AIGUASOL)

1. aiguasol.coop
Condensat de projectes de recerca
shaping energy
4a jornada energia a industria-Granollers
6 de noviembre de 2019
Aprofitaments de calor residual a
industria

2. aiguasol.coop
Aiguasol Enginyeria
Cooperativa fundada en 1999 por 2 doctores
investigadores de la UPC, con sede en Barcelona,
Oiartzun y Chile.
Equipo de 26 (21 Barcelona/Oiartzun y 5 en Chile)
personas altamente calificadas (Doctores, Físicos,
Ingenieros), y totalmente dedicadas a tareas de
ingeniería energética y consultoría.
4 áreas de trabajo
 Consultoria energètica en la industria
 Consultoría Energética para la Edificación
 Consultoría Energética de Sistemas – Desarrollo.
Productos
 Desarrollo de Software

3. DESARROLLO DE SOFTWARE ESPECIALIZADO Y
PERSONALIZADO
DISTRIBUCIÓN DE SOFTWARE
ESPECIALIZADO
ASESORAMIENTO EN DESARROLLO DE
COMPONENTES
CERTIFICACIÓN DE EDIFICIOS
ASESORAMIENTO A ARQUITECTURAS
INGENIERÍA Y DIRECCIÓN DE OBRA DE
INSTALACIONES DE ENERGÍA
CONSULTORÍA SISTEMAS DE ENERGÍA EN EDIFICACIÓN Y
URBANISMO
¿Qué hacemos?
COLABORACIÓN EN PROYECTOS EUROPEOS AIE
3
CALIDAD Y VALOR AÑADIDO

4. INDUSTRIA
4
• Enfoc a consultoria i millora de processos tèrmics industrials. Integració amb
electricitat, a través de cogeneració, bombes de calor, fotovoltaica
EINSTEIN PITAGORAS
INDUS3ES CHESTER

5. INDUSTRIA
• Més enllà de solucions individuals, és important destacar que en industria,
una de les fonts més importants de millora energètica, és la integració entre
diferents actors
• La simbiosi (com fa Granollers i les companyes de simbiosy) és un primer punt
clau, i que dona molts recursos
• Un altre vector essencial (en la mateixa línia), són les comunitats
energètiques, encara que l’enfoc és, de moment, o bé ciutadà o bé energies
renovables

6. Índex
Oportunitats
Projecte Pitagoras
Projecte Chester
6 ▌
Projecte INDUS3ES
Einstein

7. 7 ▌ 7 ▌
Oportunidades
Calor baja temperatura

8. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Oportunidades:
Calor baja temperatura
8 ▌
La demanda energética de la Industria Europea se redujo en un 28% entre 1990 y 2012.
• Crisis económica,
• Desacoplamiento energético.
Aún así representa una cuarta parte de la demanda en Europa. Aproximadamente el 70%
de la demanda es con fines térmicos y el ~30 % de esa energía es desaprovechada (EDF).
Europa inmersa en una gran dependencia
energética desaprovecha:
• 2.5 millones TJ
• El 70% de la demanda de energía
total de España
Fuente: Eurostat

9. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Oportunidades:
Calor baja temperatura
9 ▌
¿Porque BAJA TEMPERATURA?  Carácter acumulativo

10. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Oportunidades:
Calor baja temperatura
10 ▌
¿Porque BAJA TEMPERATURA?  Carácter acumulativo
“… almost 60% of heat lost
is at low temperature.”
US Energy Protection Agency
Fuente:
Fuente:

11. 11 ▌ 11 ▌
Solució Pitagoras
Simbiosi amb altres
usos
Posar exemples Granollers i Manresa

12. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Concepte Pitagoras
Recuperació de calor dels fums d’un forn electric per a usos tèrmics (DH) I
elèctrics (turbina ORC)

13. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Pitagoras concepts: Electricity generation
P0790-2300 Titulo Proyecto
110503.T2.DT01
• Possibility of electricity generation from low temperature waste heat
• Good performance under varying load conditions
• Capacity for CHP operation (electricity+useful heat)

14. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Pitagoras: demonstration Brescia pilot
plant• Process flow diagram

15. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Pitagoras: technical data

16. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Pitagoras: operation performance

17. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Pitagoras: economics

18. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Pitagoras

19. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Technical challenge: discontinuity of heat source
Steam accumulator: 150 m3, allows the ORC to operate in the tap to
tap period of the furnace (aprox 15 minutes)

20. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Technical challenge: chemistry of the waste source fluid
WHRU with pneumatic cleaning system: 3 years of operation without faults

21. aiguasol.coop
Granollers
Planificació:
 Granollers: xarxa de vapor de districte per la
xona industrial.
 Integració del biogàs de l’ecoparc proper, i
biomassa.
Ertratrans
(160 ºC)
Audens
(151 ºC)
Brenntag
(70 ºC)
Murtra
(70 ºC)
Velutex
(180 ºC)
Pastas Gallo
Sec (175 ºC)
Evonik
(185 ºC)
Coty
(80ºC)
Proalan
(175 ºC) APC Europa
(175 ºC)
Pastas
Gallo
Fresc (175
ºC)
Vapor de la
xarxa
Retorn de
condensats a
la xarxa
Producció de
vapor per
l’usuari

22. aiguasol.coop
Granollers Distribució de potència
mitjana
600 m.
1.400 m.
1.600 m.
DH2 (8 MWt)
Vapor/Condensats
DN150/DN50
10,3 t/h, ∆p=0,8 bar
DH1 (14 MWt)
Vapor/Condensats
DN200/DN80
18,1 t/h, ∆p=1,4 bar
DH3 (sense generació)
Interconnectará amb DH1 i DH2
Futura xarxa de DH de Baixa
Temperatura
DH0 (18 MWt d’APC)
Vapor/Condensats DN200/DN80
23,2 t/h, ∆p=0,1 bar
i Generació (32 MWt)
Vapor/Condensats DN300/DN125
41.3 t/h, ∆p=0,1 bar
Ertratrans
(1.1%)
Audens
(7.5%)
Brenntag
(0.1%)
Murtra
(1.4%)
Velutex
(3.9%)
Pastas Gallo
Sec (13.8%)
Evonik
(6.1%)
Coty
(3.3%)
Proalan
(3.0%) APC Europa
(51.2%)
Pastas Gallo
Fresc (8,5%)
Ertratrans
(582 kW)
Audens
(3.701 kW)
Brenntag
(151 kW)
Murtra
(700 kW)
Velutex
(4.636 kW)
Pastas Gallo
Sec (6.276 kW)
Evonik
(5.000 kW)
Coty
(1.005 kW)
Proalan
(3.600 kW) APC Europa
(8.817 kW)
Pastas Gallo
Fresc (3.183 kW)

23. CAS SIMBIOSY MANRESA
El calor residual dels motors de cogeneració es troba a 500 m i 650 m, respectivament
La central de biomassa s’ubicaria als terrenys adjacents a la deixalleria del Polígon, inicialment, encara que es plantejarà un
escenari amb la central més a prop de l’hospital
Central de
Biomassa
alt1
Motor biogàs
Consorci del
Bages
Motor biogàs
EDAR
Central de
Biomassa
alt2

24. 24 ▌ 24 ▌
Solució INDUS3ES
Transformador de
Calor

25. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Transformador de Calor:
25 ▌
Temperatura
Bomba Calor Transformador de Calor

26. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Transformador de Calor:
26 ▌
Temperatura
Transformador de Calor
70 – 120 ºC
Revalorización ~ 50 K

27. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Transformador de Calor:
27 ▌
• The AHT is focused on low temperature waste heat recovery (50 – 150ºC) and its
temperature upgrade.
• The AHT recovers and revalorizes almost 50% of the waste heat, increasing quality of the
waste source becoming it reusable again in the industrial process.

28. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Transformador de Calor:
28 ▌

29. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Transformador de Calor:
Implementación Industria
29 ▌

30. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Transformador de Calor:
Implementación Industria
30 ▌
Absorption Heat Transformer Possible applications (50 – 150ºC)
Chemical and Petrochemical
Distillation and Purification
Processes
Paper Industry
Drying and Lamination
Processes
Food and Beverage Industry
Drying, sterilization, fermentation
and mold and bacteria prevention

31. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Transformador de Calor:
Implementación Industria
31 ▌

32. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Proyecto Indus3Es:
32 ▌
Design based on the characterization of the performance of an up to 50 kW prototype tested at the lab-scale. The
scaling work was performed using the Characteristic Equation Method.
Lab-Scale Components 10 kW
March 2017.
Installation and Commissioning
January – December 2019
50 kW Prototypes Tested at Lab-Level
March 2018.
200 kW Prototype Manufacturing
November 2018

33. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Proyecto Indus3Es:
33 ▌

34. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Proyecto Indus3Es:
34 ▌

35. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Proyecto Indus3Es:
35 ▌
• The implementation site at Tupras İzmit Refinery is in Plant-9 site.
• Plant-9 is the Power Plant of Tupras.

36. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Proyecto Indus3Es:
36 ▌
Condensate-steam drum (⁓ 100 ºC)
Revalorized Stream (135 ºC)
The waste heat stream  Condensate-steam drum, normally released to the atmosphere (⁓ 95 ‒ 100 °C).
Stream to be revalorized  Supply header demineralized water (⁓ 65 °C).
Waste heat stream from the tank is also used to preheat the supply header demineralized water from approximately 65 to 95 °C. The
temperature of the supply header demineralized water temperature is boosted to 135 °C with the heat supplied by the absorber of the AHT.
65 ºC
95 ºC95 ºC)
95 ºC)
25 ºC
140 ºC

37. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Mass & energy balance
37

38. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Mass & energy balance
38

39. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
PFD & P&ID
39

40. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
PFD & P&ID
40

41. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
41

42. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
42
9E-2 Heat waste stream

43. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
43
9E-2 Heat waste stream
3-8 t/h of steam at 105 degrees C

44. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
44
Stream to be reenergized

45. 45
Tüpras’ site
Stream to be reenergized
Demineralised water at 65 degrees C and
5 bar pressure

46. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
46
Space for heat exchangers

47. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
47
Space for heat exchangers

48. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
48
Cooling water supply & return

49. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
49
Cooling water supply & return
Approximately 15 degrees temperature difference throughout the year

50. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
50
AHT

51. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Tüpras’ site
51
AHT

52. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
AHT integration system
52

53. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
AHT integration system
53
Cooling
water
9E-2
Reenergized stream
Heat exchangers
Pumps AHT

54. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
54
• Task 4.5. System installation and commissioning
Overview Progress Tasks

55. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Proyecto Indus3Es:
55 ▌
• The demonstrator plant will be fully operational by December 2019.
• Monitoring and performance analysis of the prototype’s performance will provide the required information for
further design improvements.
• Finally, the results in this project will help to spread the implementation of AHT technology in the European
industrial sector.

56. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
Proyecto Indus3Es :
56 ▌
“Indus3Es: Industrial Energy and Environmental Efficiency” funded by the Horizon 2020
framework of the European Union, Project No. 680738. http://www.indus3es.eu/

57. 57 ▌ 57 ▌
Solució Chester
Bombes de calor alta
temperatura

58. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
THE CHESTER CHALLENGE

59. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement
HIGH TEMPERATURE HEAT PUMP
Development of an environmentally friendly and highly-efficient heat pump
• high heat sink temperature (130-180°C)
• very variable heat source temperatures (from 30 to 100°C)
• new refrigerants require new compressor lubricants
• High subcooling degree
• high temperature heat pump laboratory prototype
– 10 kWe
– Possibility of trying different cycle configurations and control strategies
– A previous prototype with selected refrigerant already tested in Tecnalia

60. 60 ▌ 60 ▌
Einstein:
Eina per determinar
integracions entre processos i
millors solucions

61. Einstein
La herramienta EINSTEIN es un software experto que guía al usuario a través
de todo el procedimiento de auditoría, desde la adquisición, procesamiento y
síntesis de datos hasta el diseño y la evaluación cuantitativa (energética y
económica) de soluciones alternativas.
Este octubre ha salido una nueva versión (Einstein 3.0/3.0 plus), mucho más
interactiva y fácil de utilizar

62. Moltes gràcies!

63. aiguasol.coop
alex.ivancic@aiguasol.coop
oriol.gavalda@aiguasol.coop
C/ Roger de Llúria 29, 3º 2ª E-08009 Barcelona
Astigarragako bidea, 2. 2ª planta, dcha, Mod. 8. 20180 Oiartzun
(Gipuzkoa)
(T) + 34 93 342 47 55
(T) + 34 34 943 49 20 21
aiguasol.coop