The implementation of a technology demonstration for the food processing industry, development and technology demonstrations for selected near-term, in-plant applications and advanced industrial applications of thermal energy storage are overviewed

Duscha, R. A.

English

NASA Technical Reports Server

INDUSTRIAL STORAGE APPLICATIONS 
-. 
Program Area Synopsis: 
The major tasks in  t h i s  program element are the implementation of a 
technology demonstrati on f o r  the  food processing industry, development 
and techno1 ogy demonstrati ons fo r  selected near-term, i n-pl ant 
applications and advanced i ndustri a1 applications. These tasks wi 11 be 
supported by an on-going system studies ac t i v i t y  which will assess 
advanced appl i ca t i  ons, sol ar i ndustri a1 appl i ca t i  ons, and heat transport  
requirements. An important adjunct t o  t h i s  a c t i v i t y  i s  the continued 
implementation of technology t ransfer  through information col lect ion and 
dissemi nation. 
https://ntrs.nasa.gov/search.jsp?R=19800014307 2020-03-21T18:14:36+00:00Z

INDUSTRIAL STORAGE APPLICATIONS 
OVERVIEW 
Rudolph A. Duscha 
NASA Lewis Research Center 
S i g n i f i c a n t  conservat ion b e n e f i t s  and the  s u b s t i t u t i o n  o f  domestic 
n o n - c r i t i c a l  f u e l s  f o r  c r i t i c a l  f u e l s  ( o i l  and na tu ra l  ' gas) are poss ib le  
through the  use o f  thermal energy storage'(TES) o f  3ndus t r i a l  process and 
r e j e c t  heat f o r  subsequent use. The use of TES can e i t h e r  p rov ide  
conservat ion through r e j e c t  energy recovery and reuse o r  permi t  a  s h i f t  i n  
fue l  f rom o i l  or na tu ra l  gas t o  other  n o n - c r i t i c a l  f u e l s .  One o f  t h e  
goals o f  the  Department o f  Energy's (DOE) D i v i s i o n  o f  Energy Storage 
Systems i s  t o  p rov ide  t h e  storage techno1 ogy capabi 1 i ty  t o  prov ide  ' a t  
l e a s t  10% o f  the i n d u s t r i a l  process heat or energy requirements o f  t he  
U.S. i n d u s t r y  by t h e  year  2000. The purpose of I n d u s t r i a l  Storage 
Appl icat ions,  one element o f  DOE's Thermal Energy Storage Program, i s  t o  
develop TES systems capable o f  c o n t r i b u t i n g  t o  the  achievement o f  D O E ' S  
goal f o r  the year 2000. 
I n  order t o  achieve t h i s  long range goal i t  i s  c lea r  t h a t  i n  t he  mid-term 
t ime frame ( C Y  85-90) demonstrati on o f  conservat ion o f  s i g n i f i c a n t  amouits 
o f  c r i t i c a l  f u e l s  i s  requi red.  The groundwork t o  do t h i s  was s t a r t e d  w i t h  
an Energy Research and Development Admin is t ra t ion  (ERDA) funded study t o  
determi ne the economic and techn ica l  f e a s i b i l i t y  o f  TES i n  con junc t ion  
w i t h  waste heat recovery (Ref. 1) .  This  study was d i r e c t e d  toward 
i d e n t i f y i n g  i n d u s t r i a l  processes charac ter ized by f l u c t u a t i n g  energy 
a v a i l a b i l i t y  and/or demand, a key c r i t e r i o n  f o r  TES a p p l i c a b i l i t y .  
A t  l e a s t  twenty (20) i n d u s t r i e s  were i d e n t i f i e d  as areas where thermal 
energy storage had p o t e n t i a l  f o r  a p p l i c a t i o n  t o  some degree. A f te r  t he  
conclus ion o f  t h i s  general f e a s i b i l i t y  study program, ERDA issued a 
Program Research and Development Announcement (PRDA). This  PRDA requested 
proposals f o r  i n d i v i d u a l  s tud ies  of s p e c i f i c  i n d u s t r i e s  which were t o  be 
se lec ted  by each proposer. The o v e r a l l  o b j e c t i v e  was t o  i d e n t i f y  s p e c i f i c  
app l i ca t i ons  o f  TES i n  s p e c i f i c  i n d u s t r i e s  through these system studies,  
and i n  subsequent work develop and val  i date p o t e n t i  a1 systems, demonstrate 
f e a s i b i l i t y  on a l a r g e  scale, and then t r a n s f e r  t he  technology t o  the  
t o t a l  i ndustry  t o  r e s u l t  i n  w i  despread implementation. 
As a r e s u l t  o f  t h i s  PRDA (and a f t e r  the then recent  metamorphosis from 
ERDA t o  DOE) DOE's D i v i s i o n  o f  Energy Storage Systems awarded f i v e  
cont rac ts  t o  s tudy f i v e  i n d u s t r i e s  w i t h  p o t e n t i  a1 s i g n i f i c a n t  energy 
savings through t h e  use o f  TES systems. These i n d u s t r i e s  were paper and 
pulp, food processing, s t e e l  and i ron ,  cement, and pr jmary  aluminum. The 
aluminum study produced r e s u l t s  t h a t  were app l i cab le  t o  d i s t r i c t  heat ing  
systems. Because o f  t h i s  d i s t i n c t  a p p l i c a t i o n  the  aluminum s tudy  r e s u l t s  
(Ref. 2) and subsequent fo l low-on work are being discussed under B u i l d i n g  
Heat ing and Cool ing App l i ca t i ons  and w i l l  no t  be discussed here. 
The other four system studies were conducted w i t h  each one having a 
similar generalized task breakdown structure.  An analytical survey was 
conducted for  each industry to  determine the potenti a1 Aotal recoverable 
energy. Candidate storage systems and applications for  usi ng the 
recovered energy were evaluated. Prel imi nary conceptual designs were 
evolved for which performance analyses were conducted. Economic analyses 
were made fo r  the most promising designs, and the potential technical 
f e a s i b i l i t y  and economic benefits were assessed and summarized. Any 
development required was identified,  and each study was concluded w i t h  a 
comercialization plan being formulated. 
The resul ts  of these studies indicated tha t  within these industries 
thermal energy storage of process and r e j ec t  heat for subsequent in-pl ant 
use appears to  be economically and technically feasible  with significant 
near-term conservation benefits. Potential annual fuel savings with large 
scale implementati on of near-term TES systems for  these industries i s  over 
9 x 106bbl of o i l .  This savings i s  due to  recuperation and storage i n  
the food processing industry, direct fuel substi tution in the paper and 
pulp industry, and reduction i n  e l ec t r i c  u t i l i t y  peak fuel use through 
in-plant production of e l e c t r i c i t y  from ut i l iza t ion  of reject  heat i n  the 
s teel  and cement industries. 
The technology identified f a l l s  into three categories: (1)  Existing 
operational TES system applications for  which detailed information has not 
been made pub1 i c; ( 2 )  Promisi ng system appl i cations that  involve current 
technology, require no development, and are ready fo r  imnedi a te  technology 
demonstrati on to s t  imul ate  cornmerci a1 introduction; and ( 3 )  Promi s i  ng 
system appl i cati  ons that  require development pri or to  a 1 arge scale 
industrial  technology demonstration. 
.The paper and pulp application (category 1)  i s  summarized in Figure 1. 
For mills w i t h  hog fuel (wood waste) boilers with excess steam generation 
capacity, TES would allow the substi tution of more hog fuel for  oi l  or 
natural gas. Typically, the base loaded hog fuel boilers with slow 
response times are augmented by oil  or gas boilers to  meet rapid steam 
demands. TES through the use of a steam accumul ator can provide a 1 oad 
smoothing capabili ty that  would direct ly  reduce the use of oi l  or natural 
gas. The resul ts  of th i s  study are presented in Ref.3. 
Mil 1 s ,  both i n  t he  U.S. and the Scandanavian countries, have been 
identified with such TES systems i n  place. However, information on these 
systems has not been made publicly available. A contract will soon be 
awarded for  a program to obtain, analyze and disseminate th i s  information 
t o  the U.S. paper and pulp industry. A more detailed discvssion of th i s  
program appears l a t e r  i n  t h i s  same section. 
The food processing a p p l i c a t i o n  (category 2)  i s  sumnarized i n  F igu re  2. 
TES i n  con junc t ion  w i t h  recupera t ion  can reduce energy consunption i n  a 
t y p i c a l  f ood  canning p lan t .  Preheat ing f resh make-up water through 
convent ional heat exchange w i t h  t h e  waste hot  water stream r e s u l t s  i n  a 
d i r e c t  conservat ion o f  energy. I n  addi t ion,  when t h e  process demands 
d im in i sh  w h i l e  waste hot  water i s  s t i l l  avai lab le,  t he  heated incoming 
f r e s h  water can be d i v e r t e d  t o  storage. Hot water t h a t  accumulates i n  
storage dur ing  the  product ion  pe r iod  would then be used du r ing  t h e  
equipment clean-up per iod.  Resu l ts  of t h i s  study are presented i n  Ref. 4 .  
It was concluded t h a t  waste heat recovery f rom se lec ted  food processes i s  
t e c h n i c a l l y  f eas ib le  and can be performed economical ly us ing  a v a i l  able, 
o f f - t h e - s h e l f  hardware. Therefore, a con t rac t  i s  being negot iated t o  
proceed w i t h  a technology demonstration i n  a food canning p lan t .  Th is  
demonsti-ation w i l l  be used t o  evaluate actual  hardware performance, t o  
op t im ize  t h e  system design, and t o  determine actual  costs and b e n e f i t s  
r e s u l t i n g  f rom the  waste heat recovery and storage system. The r e s u l t s  
w i l l  then be p u b l i c i z e d  t o  encourage t h e  i n s t a l l a t i o n  o f  s i m i l a r  waste 
heat recovery  systems w i t h i n  the  food processing indus t ry .  
The s tee l  and i r o n  a p p l i c a t i o n  (category 3 )  i s  sumnarized i n  F igu re  3. 
Hot gas i n  the pr imary  fume evacuat ion system o f  e l e c t r i c  arc s t e e l  
reme l t i ng  furnaces i s  t h e  r e j e c t  heat energy source. The fume stream 
would charge a s o l i d  sens ib le  heat storage packed bed. Discharge o f  the  
TES system through a heat exchanger would generate steam t o  d r i v e  a 
turbogenerator.  TES i s  used t o  permi t  e l e c t r i c  power t o  be generated 
dur ing  peak demand t imes i ns tead  of cont inuously. The economic b e n e f i t s  
t o  be der ived from the  use o f  TES fo r  peak power generat ion i s  a d i r e c t  
f u n c t i o n  o f  e i t h e r  a demand charge, t ime o f  day p r i c i n g ,  or  a combination 
o f  both. Resu l ts  of t h i s  s tudy are presented i n  Ref. 5. 
Although the  TES concept o f  t h i s  study y ie lded  favo rab le  p r e d i c t i o n s  o f  
c r i t i c a l  f u e l  d i s p l  acement and investment returns,  the  approach i s  no t  
ready t o  be app l i ed  d i r e c t l y  t o  a f u l l  sca le  demonstration w i thout  an 
i n t e r i m  concept development period. Therefore, any f u r t h e r  work w i l l  have 
t o  be as a r e s u l t  o f  compet i t ion  w i t h  other app l i ca t i ons  i n  a s i m i l a r  
s t a t e  o f  readiness. This  w i l l  be discussed f u r t h e r  a f t e r  the  next  system 
study discussion. 
The cement a p p l i c a t i o n  (ca tegory  3 )  i s  sumnarized i n  F igu re  4. Hot gas 
f rom a long, dry-process cement k i l n  would be used i n  a waste heat b o i l e r  
t o  produce steam f o r  d r i v i n g  a turbogenerator  t o  produce e l e c t r i c i t y  f o r  
in-process use. Approximately 80-90% o f  t h e  k i l n  e x i t  gas would go 
d i r e c t l y  through the waste heat b o i l e r  w i t h  the  r e s t  'being used t o  charge 
a s o l i d  sens ib le  heat storage packed bed. When t h e  k i l n  i s  down f o r  
maintenance the packed bed would be discharged through the  waste heat 
b o i l e r  thereby e l  i m i  na t i ng  a power demand charge which cou ld  be 
s i g n i f i c a n t .  Resu l ts  o f  t h i s  s tudy are presented i n  Ref. 6. 
The r e s u l t s  o f  t h e  cement study are s i m i l a r  t o  those o f  t h e  s tee l  study. 
Favorable p r e d i c t i o n s  of c r i t i c a l  fue l  savings and investment re tu rns  
,resul ted, bu t  an i n t e r  im concept development p e r i o d  would be requi red.  
A procurement a c t i v i t y  i s  i n  progress fo r  the  development and technology 
demonstrati on o f  thermal energy storage systems f o r  i n d u s t r i a l  process and 
r e j e c t  heat app l ica t ions .  This  w i l l  be a compet i t i ve  procurement w i t h  
mu1 t i p l e  awards p l  anned. Because o f  t he  pending con t rac ts  i n v o l v i n g  TES 
i n  the paper and pu lp  and food processing i ndus t r i es ,  these i n d u s t r i e s  are 
being excluded f rom t h i s  procurement. The emphasis of t h i s  procurement i s  
t o  more f u l l y  evaluate U.S. i n d u s t r y  f o r  o ther  app l i ca t i ons  o f  i n -p lan t  
use o f  s to red  thermal energy us ing  cos t -e f fec t ive  near-term techno1 ogy. 
I n -p lan t  use i s  being s p e c i f i e d  t o  preclude proposals f o r  d i s t r i c t  heat ing 
app l i ca t i ons  which are being adequately covered by t h e  fo l low-on e f f o r t  t o  
the aluminum study. 
The o b j e c t i v e  o f  t h i s  procurement i s  t o  develop, i f  needed, and 
demonstrate TES systems t h a t  of fer  t he  p o t e n t i a l  of sav ing s i g n i f i c a n t  
q u a n t i t i e s  o f  energy or  c r i t i c a l  f u e l s  i n  t h e  near-term on a c o s t - e f f e c t i v e  
basis.  S p e c i f i c  goals are to:  c o n t r i b u t e  t o  t h e  DOE goal o f  p rov id ing  
10% o f  the U.S. i n d u s t r y ' s  process heat or energy requirements by the year 
2000 through thermal energy storage; be c o s t - e f f e c t i v e  by p rov id ing  a 
r e t  urn-on- i nvestment t h a t  w i l l  s i g n i f i c a n t l y  a t t r a c t  broad sca le  
implementation; be acceptable by t h e  i n d u s t r y  as being o p e r a t i o n a l l y  safe 
and r e l i  able; and be envi ronmental ly  acceptable. Cost-shar i  ng w i l l  be an 
important  f ac to r  i n  con t rac t  awards fo r  t h i s  procurement. 
F igure  5 sumnarizes i n  a schedular form the  major a c t i v i t i e s  under the 
I n d u s t r i a l  Storage App l i ca t i ons  element. L i n e  1 shows the  con t i nu ing  
System Studies and Support ing Technology a c t i v i t y .  The PRDA system 
s tud ies  discussed i n  t h i s  paper produced s i g n i f i c a n t  r e s u l t s  t h a t  were 
t r a n s f e r r e d  t o  o ther  a c t i v i t i e s .  The Technology Trans fer  t o  Paper and 
Pulp I n d u s t r y  a c t i v i t y  i s  a n t i c i p a t e d  as being an 18 month program from 
e a r l y  1980 t o  mid-1981. The Technology Demonstration f o r  Food Processing 
I n d u s t r y  a c t i v i t y  i s  a three-year  program from e a r l y  1980 t o  1983. The 
Development and Technology Demonstration f o r  Selected Near-Term In-P lan t  
App l ica t ions  i s  an t i c i pa ted  as being a f ive-year program f rom mid-1980 t o  
mid-1985. Cont inuing System Studies a c t i v i t i e s  i nc lude  Heat Transport 
Appl icat ions,  So lar  I n d u s t r i a l  App l i ca t i ons  and New o r  Advanced 
App l ica t ions .  S i g n i f i c a n t  r e s u l t s  from t h i s  a c t i v i t y  w i l l  be t r a n s f e r r e d  
i n  e a r l y  1982 t o  Development and Technology Demonstrati on f o r  Advanced 
App l ica t ions .  An important  f a c t o r  i n  a l l  o f  these a c t i v i t i e s  i s  the  
cont inued implementation o f  technology t r a n s f e r  through i n fo rma t ion  
c o l l e c t i o n  and disseminat ion. 
REFERENCES 
1. Glenn, D. R. : Technical and Economic F e a s i b i l i t y  o f  Thermal Energy 
Storage. General E l e c t r i c  Co., (COO-2258-I), 1976. 
2. Kat te r ,  L. 6.; and Haskins, R. L.: App l ica t ions  o f  Thermal Energy 
Storage t o  Process Heat and Waste Heat Recovery i n  t h e  Pr imary Aluminum 
Indust ry .  Rocket Research Co. (CONS/5080-I), 1978. 
3. Carr, J. H.: A p p l i c a t i o n  o f  Thermal Energy Storage t o  Process Heat 
Storage and Recovery i n  the  Paper and Pulp Indus t ry .  Boeing 
Engineering and Const ruc t ion  (CONS/5082-I), 1978. 
4. Lundberg, W .  L.; and Christenson, J. A.: ~ ~ ~ l i c a t i o n s  f  Thermal 
Energy Storage t o  Waste Heat Recovery i n  t h e  Food Processing Indus t ry .  
Westinghouse E l e c t r i c  Corporat ion (CONS/5002-I), 1979. 
5. Ka t te r ,  L. B.; and Peterson, D. J.: App l ica t ions  o f  Thermal Energy 
Storage t o  Process Heat and Waste Heat Recovery i n  the  I r o n  and Stee l  
Indus t ry .  Rocket Research Co. (CONS/5081- 1 ), 1978. 
6. Jaeger, F. M.; Beshore, D. G.; M i l l e r ,  F. M.; and Gartner, E. M.: 
Appl i c a t i  ons o f  Thermal Energy Storage i n  the  Cement Indus t ry .  M a r t i n  
M a r i e t t a  Aerospace (CONS/5084-I), 1978. 
S a 5 S  
INDUSTRY: PAPER AMD PULP 
HEAT SOURCES IN PAPER AND PULP  ILL 
0 EXCESS STEAM FROM HOG FUEL (WOOD W A S T E )  BOILER WRIN~ LOW 
STEAM DEMAND PERIOD 
ENERGY  ell^ USE APPLICATIONS 
D PROCESS STEAM 
0 FEEDWATER HEATING 
PECOVERY/STORAGE/REU~E SYSTEM 
0 CENERATE EXCESS STEAM DURING LOU DEMAND PERIODS 
0 STORE I N  S T E M  ACCUMULATOR 
0 PROVIDE PROCESS STEAM DIRECTLY OR USE FOR FEEDWATER 
HEATING DURING HIGH DEMAND PERIODS 
o SAVE 100,000 BBL OIL/MILL ANNUALLY; 30% RETURN ON INVESTMENT 
. - -  
F igure  1 
INDUSTRY: FOOD PROCESSING 
CONTRACTOR: WESTINGHOUSE/HEI NZ 
HEAT SOURCES IN FOOD PROCESSING PLANTS 
0 HOT WASTE WATER FROM FOOD PROCESSING 
ENERGY END USE APPLICATIONS 
0 EQUIPMENT CLEAN UP 
0 PREHEAT INCOMING WATER FOR FOOD PROCESSING 
&JOVERY/STOR - - .  . 
0 CAPTURE HEAT FROM WASTE WATER 
o STORE ax I N  HOT WATER TANK; USE REST FOR PREHEAT 
0 USE TOPPED-OFF STORED WATER FOR EQUIPMENT CLEAN UP 
0 SAVE 3-5% OF FUEL USAGE; 3 YEAR PAYBACK PERIOD 
- -. - 
F igure  2 
92 
HEAT SOUICES IN ELECTRIC k c  STEEL PLUT 
0 -1MWY F W E  STREAM FROM ELECTRIC ARC F U N A C E  
SOU rn STACK GASES 
BAR R I L L  FIRNACE STKK U S E S  
EN~asr END USE ~ P L I C A T I O ~ S  
0 ELECTRICAL ENERGY 6ENERATIOY 
INGOT PREHEATING 
C W W S T I O Y  AIR PREHEATING 
S C R W  PREHEATl#G 
0 CAPTURE HEAT FROM ELECTRIC ARC FURMACE F W E  STREAM 
0 STORE I N  PACKED BED 
0 =YERATE STEAM TO PRODUCE ELECTRICITY W R I N G  PERIODS 
HEAT SOWCES IN DRY KILN CEMENT RANTS 
0 K I L N  E X I T  M S  
0 CLINKER COOLER WASTE GAS 
K I L N  S M L L  M A T  LOSS 
ENERGY END USE ~RICATI~HIS 
0 ELECTRICAL ENERW YNERATIOY 
RAM MATERIAL DRY116 
F W L  W Y I N G  
O I L  V I S C 0 5 l T V  R E D U t T l O l  
0 C I T T U E  M A T  F R W  K I L N  E X I T  U S  U D  CLINKER COOLER WlSTE U S  
0 STORE I N  PACKED BED 
0 SLNERATE STEAM TO R O M E  E L E C R I C I T Y  WHEN K I L I  I S  WI* 
0 SAVE 4 1 106 BBL O I L  MWUALLY F a  INDUSTRY: 5 a  R O l  F a  
C R B I N E O  STSTER 
INNSTRIAL T H E W L  STORAGE APPLICATIONS 
S M Y  - SCHEDULE 
v TRANSFER TECHMOLOGY TO INDUSTRY 
1 TMNSFER RESULTS 
ACTIVITIES 79 
Figure 5 
8 0  
SYSTEH STUDIES r SUPPORTING TECHNOLOGY 
I v 
81 83 8 2  
v 
v 
6 
84 
TECHMILMY TRMSFER TO PAPER 4 PULP INDUSTRY 
TEUIIIOLW W3011STRATION FOR FOOD PROCESSIffi 
85 
INDUSTRY 
DMLOPNMT L TECHMLOGY DWOATRATION FOR 
SEECTED IIEAR-TEM IN-PINT APPLICATIONS 
DEKLOPNENT L TECHNOLOGY DEMl6TR4TION FOR 
AWAKED APPLICATIONS 
1 


Industrial storage applications overview

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