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Latent Heat Storage for Waste Heat Recovery in the Energy Industry

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Latent Heat Storage for Waste Heat Recovery in the Energy Industry ( latent-heat-storage-waste-heat-recovery-the-energy-industry )

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Energies 2021, 14, 365 2 of 13 integration of systems through process optimisation and industrial symbiosis [3]. The SET-Plan also identified the EII of iron and steel production as well as the chemical and the pharmaceutical sectors as the sectors with the most significant potential for energy savings and high socio-economic importance [5] due to the generation of value-added products and the associated job creation. Furthermore, the ceramic sector is also a relevant example within the manufacturing industry because of the high fuel consumption required in firing, drying, and spray drying processes [6]. In the industrial sector, a substantial part of the energy is converted into waste heat due to inefficiencies, of which 50% corresponds to temperatures above 250 ◦C [7]. Aligned to the raising awareness of global warming effects and increment of fuel prices, waste heat recovery and furnace retrofitting have a direct and beneficial impact on the efficiency of the process and, consequently, on the reduction of consumption, environmental pollution, and size and cost of equipment. Especially in the EII sectors [8], there exists a great po- tential to take advantage of the exhaust steam or gases, especially at high temperatures. Jouhara et al. [9] comprehensively reviewed waste heat recovery methodologies and tech- nologies used for industrial processes in steel and iron, food, and ceramic sectors, pointing out the applicability of technologies based on sensible heat exchange such as recuperators, regenerators, passive air preheaters, heat exchanger based on flat plates, economisers, and units such as waste heat boilers and run around coil. Over the total waste heat potential in the EU (300 TWh/yr), the representativity share corresponds to low-grade below 200 ◦C (33%), medium-grade (25%), and high-grade (33%) waste heat above 500 ◦C [6]. Among the energy efficiency alternatives, it is worth mentioning the relevance of ther- mal storage systems (TES) to increase the system flexibility and to mitigate the decoupling between energy generation and demand. Several successful cases have been found in other fields, such as the integration of storage solutions in buildings and renewable energies production towards sustainable energy [10]. Regarding its application on industrial envi- ronments, Gibb, et al. [11] pointed out that a major challenge is identifying the performance factors that make a TES suitable and consequently matching the most beneficial storage systems with an appropriate process. It needs a precise method and an evaluation proce- dure for TES systems integrated into different applications, such as the one developed in Annex 30 of the International Energy Agency (IEA) technology collaboration programme of Energy Conservation through Energy Storage (ECES) [12]. This methodology evaluates TES systems integrated into processes and defines some process analysis guidelines to do so. However, this methodology would need to be further adapted to the EII sector application and integration more specifically. Recently the main challenge is to focus on waste heat recovery (WHR) and TES sys- tems working at high temperatures. In this scenario, there is a major limitation in terms of material availability and operating conditions [13]. Therefore, the selection of suitable mate- rial is a crucial aspect of the PCM-TES design [14]. In this sense, Fernandes et al. [15] carried out an in-depth analysis for high-temperature TES materials. Main results highlighted the metal foams as a promising alternative to inorganic salts to improve the thermo-mechanical properties. At medium temperature waste heat quality, Ferreira et al. [16] analysed the environmental behaviour of twenty industrial applications combining four PCM-TES sys- tems varying the type of salt (PCM) incorporated and obtaining very promising results. At high-temperature ranges, Royo et al. [17] proposed PCM-TES configurations working at high temperatures, namely, a shell and tube structure with PCM contained into double concentric tubes, a PCM-TES system formed by two heat exchanger (HX) modules and a heat transfer fluid (HTF), a crossflow system in a double HX chamber filled with PCM tubes, and an interchangeable crossflow with finned PCM tubes. Overall, inorganic molten salts and metal-based alloys could be used as PCM at high temperatures. All things considered, this paper proposes a decision-support system (DSS) to find suitable PCMs working at high temperatures. The methodology was based on a techno- economic analysis and environmental assessment to determine the potential for improving efficiency, reducing environmental impact, and cost savings. Different indicators were

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