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A prototype of a thermal insulation system to offer high selectivity of the solar gain regarding the solar incidence angle (SATIS) was applied to a typical solid brick masonry for existing buildings in Germany. Light conducting elements (LCEs) inclined at 19 ° were incorporated in SATIS, which equals the average solar noon angle in southern Germany during winter. The entire wall construction was experimentally investigated in a differential climatic chamber test bench at four different irradiation angles according to a dynamic test procedure. In addition, a conventional wall construction (CWC) has been measured. At SATIS’ design angle of 19 °, the SATIS wall construction shows a solar gain (SG) of 394.5 Wh/m², while the SG of the CWC amounts to only 25.4 Wh/m². The validated transient model of the SATIS wall construction showed that, at the end of the irradiation period of the dynamic test procedure (8 h), the solar heat penetrates to a depth of 253 mm and 111 mm inside the 385 mm thick brick wall masonry at the irradiation angles of 19 ° and 50 °, respectively. During the same time, the stored solar energy at 50 ° amounts to only 24.4 % of that stored at 19 °.
The currently still high fossil energy demand is forcing the glass industry to search for innovative approaches for the reduction in CO2 emissions and the integration of renewable energy sources. In this paper, a novel power-to-methane concept is presented and discussed for this purpose. A special focus is on methods for the required CO2 capture from typical flue gases in the glass industry, which have hardly been explored to date. To close this research gap, process simulation models are developed to investigate post-combustion CO2 capture by absorption processes, followed by a techno-economic evaluation. Due to reduced flue gas volume, the designed CO2 capture plant is found to be much smaller (40 m3 absorber column volume) than absorption-based CO2 separation processes for power plants (12,560 m3 absorber column volume). As there are many options for waste heat utilization in the glass industry, the waste heat required for CO2 desorption can be generated in a particularly efficient and cost-effective way. The resulting CO2 separation costs range between 41 and 42 EUR/t CO2, depending on waste heat utilization for desorption. These costs are below the values of 50–65 EUR/t CO2 for comparable industrial applications. Despite these promising economic results, there are still some technical restrictions in terms of solvent degradation due to the high oxygen content in flue gas compositions. The results of this study point towards parametric studies for approaching these issues, such as the use of secondary and tertiary amines as solvents, or the optimization of operating conditions such as stripper pressure for further cost reductions potential.
Simulation and Techno-Economic Analysis of a Power-to-Hydrogen Process for Oxyfuel Glass Melting
(2021)
As an energy-intensive industry sector, the glass industry is strongly affected by the increasingly stringent climate protection targets. As established combustion-based production systems ensure high process stability and glass quality, an immediate switch to low greenhouse gas emission processes is difficult. To approach these challenges, this work investigates a step-by-step integration of a Power-to-Hydrogen concept into established oxyfuel glass melting processes using a simulation approach. This is complemented by a case study for economic analysis on a selected German glass industry site by simulating the power production of a nearby renewable energy park and subsequent optimization of the power-to-hydrogen plant performance and capacities. The results of this study indicate, that the proposed system can reduce specific carbon dioxide emissions by up to 60%, while increasing specific energy demand by a maximum of 25%. Investigations of the impact of altered combustion and furnace properties like adiabatic flame temperature (+25 °C), temperature efficiency (∆ξ = −0.003) and heat capacity flow ratio (∆zHL = −0.009) indicate that pure hydrogen-oxygen combustion has less impact on melting properties than assumed so far. Within the case study, high CO2 abatement costs of 295 €/t CO2-eq. were determined. This is mainly due to the insufficient performance of renewable energy sources. The correlations between process scaling and economic parameters presented in this study show promising potential for further economic optimization of the proposed energy system in the future.
This work aims at investigating the kinetic mechanisms of the reduction/oxidation (redox) reactions of iron oxide/iron pellets under different operating conditions. The reaction principle is the basis of a thermochemical hydrogen storage system. To simulate the charging phase, a single pellet consisting of iron oxide (90% Fe2O3, 10% stabilising cement) is reduced with different hydrogen (H2) concentrations at temperatures between 600 and 800 °C. The discharge phase is initiated by the oxidation of the previously reduced pellet by water vapour (H2O) at different concentrations in the same temperature range. In both reactions, nitrogen (N2) is used as a carrier gas. The redox reactions have been experimentally measured in a thermogravimetric analyser (TGA) at a flow rate of 250 mL/min. An extensive literature review has been conducted on the existing reactions’ kinetic mechanisms along with their applicability to describe the obtained results. It turned out that the measured kinetic results can be excellently described with the so-called shrinking core model. Using the geometrical contracting sphere reaction mechanism model, the concentration- and temperature-dependent reduction and oxidation rates can be reproduced with a maximum deviation of less than 5%. In contrast to the reduction process, the temperature has a smaller effect on the oxidation reaction kinetics, which is attributed to 71% less activation energy (Ea,Re=56.9 kJ/mol versus Ea,Ox=16.0 kJ/mol). The concentration of the reacting gas showed, however, an opposite trend: namely, to have an almost twofold impact on the oxidation reaction rate constant compared to the reduction rate constant.
This work aims at investigating the reduction/oxidation (redox) reaction kinetics on iron oxide pellets under different operating conditions of thermochemical hydrogen storage. In order to reduce the iron oxide pellets (90% Fe2O3, 10% stabilizing cement), hydrogen (H2) is applied in different concentrations with nitrogen (N2), as a carrier gas, at temperatures between between 700 ∘C and 900 ∘C, thus simulating the charging phase. The discharge phase is triggered by the flow of a mixture out of steam (H2O) and N2 at different concentrations in the same temperature range, resulting in the oxidizing of the previously reduced pellets. All investigations were carried out in a thermo-gravimetric analyzer (TGA) with a flow rate of 250mL/min. To describe the obtained kinetic results, a simplified analytical model, based on the linear driving force model, was developed. The investigated iron oxide pellets showed a stable redox performance of 23.8% weight reduction/gain, which corresponds to a volumetric storage density of 2.8kWh/(L bulk), also after the 29 performed redox cycles. Recalling that there is no H2 stored during the storage phase but iron, the introduced hydrogen storage technology is deemed very promising for applications in urban areas as day-night or seasonal storage for green hydrogen.
An innovative adsorber plate heat exchanger (APHE), which is developed for application in adsorption heat pumps, chillers and thermal energy storage systems, is introduced. A test frame has been constructed as a representative segment of the introduced APHE for applying loose grains of AQSOA-Z02. Adsorption kinetic measurements have been carried out in a volumetric large-temperature-jump setup under typical operating conditions of adsorption processes. A transient 2-D model is developed for the tested sample inside the setup. The measured temporal uptake variations with time have been fed to the model, through which a micro-pore diffusion coefficient at infinite temperature of 2 E−4 [m2s−1] and an activation energy of 42.1 [kJ mol−1] have been estimated. A 3-D model is developed to simulate the combined heat and mass transfer inside the APHE and implemented in a commercial software. Comparing the obtained results with the literature values for an extruded aluminium adsorber heat exchanger coated with a 500 μm layer of the same adsorbent, the differential water uptake obtained after 300 s of adsorption (8.2 g/100 g) implies a sound enhancement of 310%. This result proves the great potential of the introduced APHE to remarkably enhance the performance of adsorption heat transformation appliances.
The effect of both heat and mass transfer characteristic lengths (HTCL, MTCL) of two different adsorber plate heat exchangers (APHE), for application in an adsorption chiller, on the adsorption and desorption kinetics is investigated. Three representative test frames (TF1-TF3) are prepared to examine small-scale adsorbent samples of the microporous silica gel (Siogel of Oker-Chemie, Germany) applying the volumetric large-temperature-jump methodology at different operating conditions. Based on the obtained kinetic data, an analytical model has been developed to predict the specific cooling power (SCP) and the coefficient of performance (COP) of a single-bed adsorption chiller comprising the studied APHEs. It turned out that, within the tested range of HTCL and MTCL, it can be concluded that, the adsorption kinetics are mainly influenced by the MTCL, while the desorption kinetics are dominated by the HTCL of the adsorbent domain. Applying Siogel as loose pellets inside a newly introduced APHE results in of 423.3 and 182.7 W⋅kg−1, at the evaporator temperatures of 15 °C and 5 °C, respectively. Herein, the condenser and adsorber-end temperatures amount to 30 °C and the desorption-end temperature to 90 °C. The corresponding s amount to 0.50 and 0.40, respectively, which represent quite promising results for further design optimizations.
In order to comply with future emission regulations, the use of particulate filters in vehicles with direct injection gasoline engines is essential. The current amount of soot and ash in the filter is calculated by a soot load model in the electronic control unit in combination with a differential pressure sensor determining the pressure drop over the particulate filter. Active regeneration is initiated if the calculated amount of soot or the measured differential pressure is too high. This is associated with additional fuel consumption. An on-board diagnosis for the particulate filter is currently not part of the Euro 6d emission standard. For future exhaust emission standards, on-board diagnosis or active monitoring of the particulate filter is conceivable. One of the benefits of monitoring is the fact that unnecessary active regenerations can be avoided. As a result, there is no additional fuel consumption due to misinterpretations of the amount of soot in the filter. For active monitoring of the particulate filter, a radiofrequency (RF-) sensor, that detects the soot loading of the filter with electromagnetic waves directly, can be used. Such a system has the advantage that by utilizing the filter as a sensor more precise information about the current state of the filter, e.g. a possible damage, can be provided. Worst-case considerations of filter damages, tested at an engine test bench show the advantages which are entailed by a system like that. By means of partial regeneration of the particulate filter it is demonstrated how the remaining amount of soot in the filter can be detected in a better way in comparison to the differential pressure sensor by using the RF-sensor.
Due to the very high fossil energy demand, the glass industry is looking for innovative approaches for the reduction of CO2 emissions and the integration of renewable energy sources. In this paper, we present a novel power-to-gas concept, which has no impact on established melting processes and discuss it for this purpose. A special focus is set on the required CO2 capture from typical flue gases in the glass industry, as this process has not been investigated in detail yet. We used a process simulation approach to investigate post-combustion CO2 capture by absorption processes, followed by a techno-economic evaluation. Our investigations found the designed CO2 capture plant to be approx. 400 times smaller than absorption based CO2 separation processes for conventional power plants. Due to the many options for waste heat utilization, the waste heat required for CO2 desorption can be generated in a particularly efficient and cost-effective way. The resulting CO2 avoidance costs range between 41-42 €/t CO2, depending on waste heat utilization for desorption, and thus offer a cost effective way of CO2 removal from glass industry melting processes. These costs are well below the values of 50-65 €/t CO2 described so far for comparable industrial applications. In addition, we describe optimization options, like solvent and process improvements, to enable further cost reductions. These results motivate further research and development on the overall process presented in this work.