High-Temperature Heat Pumps for Electrification and Cost-Effective Decarbonization in the Tissue Paper Industry
Abstract
:1. Introduction
1.1. Energy Demand in the European Pulp and Paper Industry
1.2. Process Heat Decarbonization through Electrification
1.3. High-Temperature Heat Pumps: Technologies, Costs, and Refrigerants
1.4. Research and Evaluations on HTHP Implementation in Industries
1.5. Scope of the Paper
2. Materials and Methods
2.1. Cases
- The first represents the current state-of-the-art plants with a high degree of thermal recovery.
- The second is characterized by the replacement of the natural gas boiler with an electric one.
- The third introduces the high-temperature heat pump to enhance waste heat recovery.
2.1.1. Layout 1: Natural Gas Boiler
2.1.2. Layout 2: Electric Boiler
2.1.3. Layout 3: HTHP
2.2. Heat Pump Definition
2.2.1. Waste Heat Source
2.2.2. High-Temperature Heat Pump Layout
2.2.3. Refrigerants
- The critical temperature of the refrigerant should be higher than or near the supply temperature to allow the optimization algorithm to explore a reasonable range of feasible solutions. Consequently, several fluids, such as ammonia, were excluded from consideration.
- The evaporation pressure of the refrigerant at the temperature achievable in the evaporator, using waste heat, should be above atmospheric pressure. The expected evaporation temperature is around 45 °C, so it has assumed that refrigerants must have an evaporation pressure higher than 1.01325 bar (1 atm) at 40 °C. Therefore, despite their proven performance [22,23], water, acetone, and benzene were not considered. Additionally, R365MFC, identified in [23] as the best-performing fluid among those studied, was excluded due to its evaporation pressure being slightly below 1 atm at 40 °C.
2.2.4. Optimization Process and Analysis of Environmental Sustainability
- COP, as defined in Equation (1).
- Volumetric heating capacity (VHC), defined as the ratio between the produced heat flow rate and the refrigerant volumetric flow rate at the compressor inlet. This value is interesting from a technological viewpoint, as the higher it is, the smaller the system dimensions will be.
- Compression ratios (β) of the bottom and top cycle, which can be helpful to argue the number of stages required by the actual compressors.
- Water recovery, defined as the additional water condensed—and recovered—compared to the base case. While water recovery is not the focus of this article, paper companies are called upon to make an effort to manage water resources efficiently and with minimal waste. This issue is intrinsically linked to the broader problem of global warming because one of the potential consequences of climate change is water scarcity [41].
2.2.5. Economic Analysis
3. Results and Discussion
3.1. Heat Pump Performances
3.1.1. Water Recovery
3.1.2. Optimization Results
- Maintain the minimum pinch point of 20 °C, imposed as a constraint in the optimization,
- Extract a significant amount of heat flow rate from the flue gas to reduce the demand for electricity,
- Keep the refrigerant pressure high to reduce the compression ratio, thus improving the COP and maintaining evaporating pressure above atmospheric conditions.
- Maintaining the maximum temperature of discharge from the bottom compressor below 200 °C. This also involves the superheating that the fluid receives at the IHX.
- Limiting the compression ratio to increase COP.
- Maintaining a pinch point of 20 °C at the condenser.
- Maintaining the maximum temperature of discharge from the top compressor below 300 °C.
3.2. Analysis of Environmental Sustainability
3.3. Economic Analysis Results
Comparing HTHP and Other Decarbonization Strategies
4. Conclusions
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Flow | Specifications |
---|---|
Hot air | ṁ = 11 t/h |
Process water | ṁ = 5.5 t/h |
Exhaust air 1 | ṁ = 16.5 t/h |
T = 310 °C | |
Exhaust air 2 | ṁ = 15 t/h |
T = 75 °C | |
Recovered water 1 | ṁ = 1.5 t/h |
Process condensate * | ṁ = 4 t/h |
p = 8 bar | |
HP saturated steam | p = 17 bar |
Blow-through steam | ṁ = 5 t/h |
p = 8 bar | |
Saturated steam to Yankee * | ṁ = 9 t/h |
p = 9 bar | |
Fuel 1 | Pth = 3300 kWth |
Fuel 2 | Pth = 2700 kWth |
Electric power | Pel = 2400 kWe |
Saturated steam from HTHP | ṁ = 4 t/h |
p = 9 bar | |
Saturated steam to Yankee | ṁ = 9 t/h |
p = 9 bar | |
Electric power MVR | Pel = 40 kWe |
Flow (dry air) | 3.0 kg/s |
Humidity | 0.37 kgH2O/kgDA |
Total flow | 15,000 kg/h |
Temperature | 75 °C |
Screw compressor (bottom cycle) | Adiabatic efficiency: 80% |
Electro-mechanic efficiency: 90% | |
Centrifugal compressor (top cycle) | Adiabatic efficiency: 85% |
Electro-mechanic efficiency: 95% |
Name | Class | Critical Point | GWP 100 | Flammability | psat,40°C |
---|---|---|---|---|---|
R245ca | HFC | 174.4 °C 39.9 bar | 726 | 1 | 1.73 bar |
R1336mzz(Z) | HFCO | 171.3 °C 29.0 bar | 2 | 0 | 1.28 bar |
n-Pentane | HC | 196.6 °C 33.7 bar | 5 | 4 | 1.16 bar |
Min. pinch point at evaporator/boiler heat exchanger | 20 °C |
Internal heat exchanger pinch point | 10 °C |
Max. temperature in the bottom cycle | 200 °C |
Max. temperature in the top cycle | 300 °C |
Min. pressure in the bottom cycle | 1.01325 bar |
Heat flow rate demand | 2300 kWth |
Country (2019) | Primary Energy Factor [42] (kWhP/kWhel) | GHG Emission Factor [43] (kgCO2/kWh) |
---|---|---|
EU | 1.96 | 0.255 |
France | 2.43 | 0.06 |
Germany | 1.75 | 0.347 |
Italy | 1.69 | 0.234 |
Spain | 1.97 | 0.214 |
Sweden | 1.44 | 0.01 |
Primary energy factor per NG | 1.1 [44] |
GHG emission factor per NG | 0.2 kgCO2/kWh [45] |
Country (2019) | NG Price (EUR/MWh) | Electric Energy Price (EUR/MWh) |
---|---|---|
EU | 26 | 86 |
France | 26 | 68 |
Germany | 26 | 100 |
Italy | 26 | 113 |
Spain | 28 | 83 |
Sweden | 39 | 53 |
Name | COP (−) | VHC (kJ/m3) | β Bottom (−) | β Top (−) | Water Recovery (t/h) |
---|---|---|---|---|---|
R245ca | 1.89 | 1650 | 11.4 | 3.8 | 1.7 |
R1336mzz(Z) | 1.90 | 1240 | 12.3 | 3.7 | 1.7 |
n-Pentane | 2.01 | 1150 | 10.8 | 3.8 | 1.8 |
Country | Specific CAPEX (EUR/kW) |
---|---|
EU | 280 |
France | 670 |
Spain | 420 |
Sweden | 1600 |
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Ciambellotti, A.; Frate, G.F.; Baccioli, A.; Desideri, U. High-Temperature Heat Pumps for Electrification and Cost-Effective Decarbonization in the Tissue Paper Industry. Energies 2024, 17, 4335. https://doi.org/10.3390/en17174335
Ciambellotti A, Frate GF, Baccioli A, Desideri U. High-Temperature Heat Pumps for Electrification and Cost-Effective Decarbonization in the Tissue Paper Industry. Energies. 2024; 17(17):4335. https://doi.org/10.3390/en17174335
Chicago/Turabian StyleCiambellotti, Alessio, Guido Francesco Frate, Andrea Baccioli, and Umberto Desideri. 2024. "High-Temperature Heat Pumps for Electrification and Cost-Effective Decarbonization in the Tissue Paper Industry" Energies 17, no. 17: 4335. https://doi.org/10.3390/en17174335
APA StyleCiambellotti, A., Frate, G. F., Baccioli, A., & Desideri, U. (2024). High-Temperature Heat Pumps for Electrification and Cost-Effective Decarbonization in the Tissue Paper Industry. Energies, 17(17), 4335. https://doi.org/10.3390/en17174335