Development of a High-Temperature Industrial Heat Pump Model with a Novel Compressor Technology

Abstract

The current global environmental crisis has resulted in increased efforts towards more efficient and sustainable industrial processes. High-temperature heat between 150 ◦C & 400 ◦C accounts for a major part of the energy demand in industrial processes. At the same time, large quantities of waste heat are unutilised at temperatures up to 200 ◦C. A heat pump could upgrade this waste heat to cover a part of the demand, resulting in considerable savings both for the planet and the operator. Nevertheless, heat pumps have seen little development in heat delivery temperatures above about 150 ◦C. This research aims to assess the current technological potential and limitations of high-temperature heat pumps. Subsequently, solutions and recommendations are developed.
Focussing on mechanical vapour compression heat pumps, a thorough understanding of such cycles is gained first. The performance of a heat pump is highly dependent on the choice of cycle setup and working fluid, with the compressor posing the largest limitations for higher temperatures. To assess these, this project develops a heat pump model which simulates many different working fluids for different component configurations. The model was subjected to two temperature domains, covering waste heats of 100 ◦C & 200 ◦C and process heat temperatures in the range of 150 ◦C to 400 ◦C.
Results were obtained for all fluids incorporated in RefProp 9.0 and showed that multistage compression with intercooling and superheating considerably improved the performance of nearly all fluids. By comparing fluids based on efficiencies, capacities, temperatures and pressures, benzene and propylcyclohexane showed the best performance for the lower and higher part of process heat temperatures, respectively. The results however also showed the potential superiority of water as it has the best efficiencies and the largest applicability range, which combines with the hazard-free & environmentally friendly nature, low cost and wide availability. The main downside of water appeared to be the persistent, unacceptably high compression temperatures, combined with large pressures and pressure ratios. It was subsequently investigated how the disadvantages of water could be handled. A solution was found in the usage of Liquid Piston Gas Compression (LPGC), in which a rising liquid column, supplied by a pump, acts as a reciprocating piston in a compression chamber. This setup conveniently allows for liquid spray injection to cool the steam upon compression and alleviates limitations on the pressure ratio. By using the same water as the liquid in the LPGC, any temperature rise is compensated by the evaporation of liquid, resulting in more steam with a lower temperature. A numerical model of this type of compressor was made in which dynamics were modelled down to individual droplets. This simplified approach provided insight into the compression path with such liquid injection and allowed the approximate determination of the required amount of spray. Results showed that the injection could cool the vapour adequately even for high temperature lifts. The LPGC was subsequently incorporated into a single-stage heat pump cycle and compared the results for other fluids using ordinary compressors. These results showed large CoP improvements of 15-25 % CoP and low discharge temperature. With that, it was shown that an environmentally friendly fluid could be used in a simple single-stage configuration and still provide the best performance compared to any other fluid.