A system for waste heat recovery from industrial chimneys

Abstract

A thermomagnetic energy recovery system designed to convert waste heat from industrial chimney (10) gases into electrical energy, characterized by a first conductive plate (21), which is positioned parallel to the chimney (10), in thermal contact with it, and generates a thermoelectric potential difference due to the temperature gradient; at least one second conductive plate (22), which is positioned parallel to the chimney (10) but is not in thermal contact with it, thereby creating a temperature difference with the first conductive plate (21); magnets (23) with thermoelectric properties, positioned between the first conductive plate (21) and the second conductive plate (22), which convert the temperature difference into electrical energy; and thermomagnetic modules (20), which include electrical connection terminals (24) to collect the generated electrical energy. Following the conversion of heat energy into electrical energy through the thermomagnetic modules (20), the resulting reduction in chimney (10) temperature causes the chimney (10) gases to condense into water, which is collected and stored in at least one water storage unit (30). Additionally, the system comprises at least one electrical storage unit (40) to store or utilize the electrical energy generated by the thermomagnetic modules (20).

Description

[0001] A SYSTEM FOR WASTE HEAT RECOVERY FROM INDUSTRIAL CHIMNEYS

[0002] Technical Field

[0003] The invention relates to a thermomagnetic energy recovery system consisting of a threelayered structure mounted on the outer surface of industrial chimneys. The system comprises magnets placed between two conductive plates. This layered structure utilizes the thermomagnetic properties of the magnets by creating a thermal gradient outside the chimney. While one of the conductive plates is exposed to the chimney temperature, the other remains at a lower temperature, generating a thermoelectric potential difference between the magnets due to this temperature difference.

[0004] This thermoelectric potential difference is directly converted into electrical energy and reused within the industrial facility. Additionally, the system effectively reduces the temperature of chimney gases, accelerating the condensation process and enabling the recovery of water from waste heat. Designed to be easily adapted around chimneys and integrated into existing infrastructure, the system is considered a significant innovation in terms of energy efficiency and waste management. This technology introduces a novel approach in the fields of energy recovery, thermal management, and environmental engineering, contributing to sustainable production practices.

[0005] State of the art

[0006] In industrial processes, waste heat recovery (WHR) systems are essential components aimed at reducing energy consumption by recovering residual heat. Although these systems have a wide range of applications, traditional WHR systems often face challenges such as limited efficiency at low temperature ranges, complex integration with existing infrastructure, and the inability to fully utilize the complete spectrum of thermal gradients present in industrial settings. These issues are particularly observed in industrial chimneys or exhaust gases from chimneys.

[0007] Existing WHR technologies primarily capture heat through recovery or regeneration, which is then used for purposes such as heating combustion air, generating steam, or enhancing thermodynamic cycles. However, these methods can be capital-intensive, require significant maintenance, and often necessitate additional cooling systems to manage excess heat that is not converted into useful energy.

[0008] Furthermore, traditional approaches have limited functionality in reducing the temperature of exhaust gases to levels where condensation can occur, leading to a missed opportunity for water recovery an increasingly critical resource in various industrial operations.

[0009] The current landscape of WHR systems presents several disadvantages, including the need for large heat exchangers, susceptibility to fouling, and inefficiencies in energy conversion. Additionally, these systems are often designed for specific thermal sources and lack the flexibility to adapt to varying temperatures and heat fluxes. This lack of adaptability leads to inefficiencies and missed opportunities for energy recovery in many industrial scenarios.

[0010] It is essential to examine the disadvantages of existing WHR systems in greater detail:

[0011] Traditional WHR systems primarily rely on large and heavy heat exchangers, which pose significant challenges in terms of installation and maintenance. The design of these heat exchangers is typically specific to a particular heat source and flow conditions, resulting in a lack of flexibility and limitations in adapting to different operational scenarios.

[0012] Maintenance is another significant drawback. Contaminants and particulates in exhaust gases accumulate in heat exchangers over time, necessitating regular cleaning and maintenance. Fouling can reduce heat transfer efficiency and lead to system failures.

[0013] Additionally, WHR systems often exhibit limited efficiency in converting waste heat into useful energy. They face particular challenges in utilizing low- temperature waste heat, as most existing technologies require high temperature differentials to operate efficiently. This results in a substantial portion of potential energy recovery being wasted.

[0014] Another critical issue in current WHR systems is the need for additional cooling during the heat-to-energy conversion process. This requirement reduces overall energy savings and diminishes the ecological efficiency of the system. High initial investment costs also present a barrier for many businesses. The installation and integration of WHR systems, especially when adapting to existing facilities, can be costly, making them less attractive for companies seeking short-term returns on investment.

[0015] Finally, WHR systems have limited effectiveness in minimizing environmental impacts beyond energy recovery. In particular, they contribute to thermal pollution and excessive water consumption, which are significant environmental concerns associated with waste heat.

[0016] Objectives of The Invention

[0017] The primary objective of the invention is to effectively recover waste heat emitted from industrial chimneys to maximize energy production while minimizing environmental impact. To achieve this goal, a three-layer thermomagnetic system has been developed, which can directly generate electrical energy from waste heat and can be easily integrated into the outer surface of the chimney. The system utilizes the temperature difference outside the chimney to activate the thermoelectric properties of magnets, thereby generating electrical energy.

[0018] Another objective of the invention is to enhance the adaptability and application flexibility of waste heat recovery technologies. The developed system can be easily adapted to different industrial chimneys and various operational temperatures. Moreover, it offers a low-cost and technically less complex solution in terms of integration into existing infrastructures.

[0019] Another objective of the invention is to effectively reduce the temperature of chimney gases, accelerate the condensation process, and thereby obtain water from waste heat. This feature is considered a significant innovation, particularly in regions where water resources are limited or in industrial applications where water conservation is crucial, as it improves resource efficiency and meets water demand.

[0020] The final objective of the invention is to enhance the energy efficiency of industrial facilities, reduce operational costs, and simultaneously create a sustainable and environmentally friendly corporate image. Thanks to its innovative design, the system aims to set a new benchmark in energy recovery and waste management by raising industry standards. This allows facilities to reduce their carbon footprint, comply more easily with environmental regulations, and achieve green energy targets.

[0021] The invention is a thermomagnetic energy recovery system designed to convert waste heat from industrial chimney gases into electrical energy in order to achieve the aforementioned objectives. The system comprises: A first conductive plate, which is positioned parallel to the chimney, is in thermal contact with it, and generates a thermoelectric potential difference due to the temperature difference, at least one second conductive plate, which is also positioned parallel to the chimney but is not in thermal contact with it, thereby creating a temperature difference between the first and second conductive plates, magnets with thermoelectric properties, positioned between the first and second conductive plates, which convert the temperature difference into electrical energy, thermomagnetic modules, which contain electrical connection terminals that collect the generated electrical energy, at least one water storage unit, which stores the water obtained from the condensation of chimney gases as a result of the reduced chimney temperature following the conversion of heat energy into electrical energy via the thermomagnetic modules, at least one electrical storage unit, which stores or utilizes the electrical energy generated by the thermomagnetic modules.

[0022] In an alternative embodiment of the invention, when the generated electrical energy is insufficient, multiple thermomagnetic modules can be connected in series via their electrical connection terminals, allowing an increase in the amount of generated electrical energy.

[0023] In another alternative embodiment of the invention, the magnets can be made from different thermoelectric materials to enhance sensitivity to temperature differences, thereby optimizing the efficiency of electrical energy conversion.

[0024] In another alternative embodiment of the invention, adding thermal insulation material to the second conductive plate reduces the impact of external ambient temperatures and ensures the stabilization of the thermoelectric potential difference obtained from chimney gases. In another alternative embodiment of the invention, the modular design of the electrical connection terminals enables the rapid detection and resolution of potential system failures, facilitating maintenance processes.

[0025] Description of Figures

[0026] Figure- 1 is a representative view of the system that enables waste heat recovery from industrial chimneys.

[0027] Figure-2 is a table showing the electricity generation curve per magnet for the system.

[0028] Explanation of Part References

[0029] 10. Chimney

[0030] 20. Thermomagnetic Modules

[0031] 21. First Conductive Plate

[0032] 22. Second Conductive Plate

[0033] 23. Magnet

[0034] 24. Electrical Connection Terminals

[0035] 30. Water Storage Unit

[0036] 40. Electrical Storage Unit

[0037] Detailed Description of The Invention

[0038] This invention introduces an innovative system for waste heat recovery from industrial chimney (10) gases, aiming to maximize energy production while minimizing environmental impact. The core component of the system is a three-layer thermomagnetic energy recovery system, which can be easily adapted to various industrial chimney (10) gases and operational temperatures. These three layers consist of the first conductive plate (21), the second conductive plate (22), and the magnets (23) placed between them.

[0039] Thermomagnetic modules (20) are mounted on the outer surface of the industrial chimney (10). The chimney (10) serves as the main framework of the system and the primary source of waste heat. The thermomagnetic modules (20) consist of two conductive plates, the first conductive plate (21) and the second conductive plate (22) with magnets (23) placed between them, as well as electrical connection terminals (24). The first conductive plate (21) is thermally connected to the chimney (10), whereas the second conductive plate (22) is thermally isolated from it, creating a temperature difference. This temperature difference activates the thermoelectric properties of the magnets (23), thereby converting waste heat directly into electrical energy. The generated electrical energy is collected via the electrical connection terminals (24) and stored or used through at least one electrical storage unit (40).

[0040] As the thermomagnetic modules (20) extract a portion of the heat from the chimney (10) gases, the chimney temperature (10) decreases, causing the chimney (10) gases to condense into water. This water is stored in at least one water storage unit (30), allowing it to be reused within the facility for various purposes.

[0041] To further increase electricity generation, the thermomagnetic modules (20) can be connected in series through their electrical connection terminals (24). This configuration enables both higher electricity output and the easy replacement of malfunctioning thermomagnetic modules (20).

[0042] The system is designed for seamless integration with existing infrastructures, offering a cost-effective and technically simple solution. Its flexibility is enhanced by its ability to be mounted on industrial chimney (10) outer surfaces without requiring major modifications. This adaptability makes it suitable for various industrial environments and operational conditions, from high- to low-temperature exhaust.

[0043] In addition to its primary function of energy recovery, the system effectively reduces the temperature of chimney (10) gases, facilitating the condensation process that accelerates water recovery from waste heat. This feature is particularly beneficial in regions with limited water resources or industrial applications where water conservation is crucial. By improving resource efficiency, the system not only meets energy demands but also supports sustainable water management practices.

[0044] The system significantly enhances the energy efficiency of industrial facilities, reducing operational costs while ensuring compliance with stricter environmental regulations. Additionally, it reduces the carbon footprint of facilities, improving overall environmental performance and strengthening the image of sustainable and eco-friendly industrial processes.

[0045] By increasing the efficiency of energy recovery and reducing the ecological impact compared to traditional waste heat recovery (WHR) systems, this invention sets a new industry standard. It eliminates the disadvantages of large, bulky heat exchangers and the maintenance challenges associated with traditional WHR systems. Furthermore, the system does not require additional cooling processes that would otherwise reduce overall energy savings and ecological efficiency in existing installations.

[0046] The application data of the invention are as follows:

[0047] The system consists of a first conductive plate (21) and a second conductive plate (22) with dimensions of 20 cm x 20 cm, containing 36 magnets (23) positioned between them. At a chimney (10) gas temperature of 80°C, each magnet (23) is capable of generating up to 150 mV of energy. Additionally, each plate affects a gas flow rate of 50,000 m3 / h, reducing the temperature by 0.4°C.

[0048] Based on calculations using Riemann summation, the system has been determined to generate an average potential of 117.15 mV per magnet (23). Furthermore, another measurement has shown that the average resistance of the system, measured with one receiver at the corner and another at the center point, is 10Q.

Claims

CLAIMS1. A thermomagnetic energy recovery system designed to convert waste heat from industrial chimney (10) gases into electrical energy, characterized by:• a first conductive plate (21), which is positioned parallel to the chimney (10), in thermal contact with it, and generates a thermoelectric potential difference due to the temperature gradient, at least one second conductive plate (22), which is positioned parallel to the chimney (10) but is not in thermal contact with it, thereby creating a temperature difference with the first conductive plate (21), magnets (23) with thermoelectric properties, positioned between the first conductive plate (21) and the second conductive plate (22), which convert the temperature difference into electrical energy, and thermomagnetic modules (20) that include electrical connection terminals (24) to collect the generated electrical energy.• at least one water storage unit (30), which stores the water obtained from the condensation of chimney (10) gases as a result of the reduced chimney (10) temperature following the conversion of heat energy into electrical energy through the thermomagnetic modules (20).• at least one electrical storage unit (40), which stores or utilizes the electrical energy generated by the thermomagnetic modules (20).

2. A thermomagnetic energy recovery system according to claim 1 , characterized in that when the generated electrical energy is insufficient, multiple thermomagnetic modules (20) can be connected in series via their electrical connection terminals (24) to increase the amount of generated electrical energy.

3. A thermomagnetic energy recovery system according to claim 1 , characterized in that the magnets (23) are made from different thermoelectric materials to enhance sensitivity to temperature differences, thereby optimizing the efficiency of electrical energy conversion.

4. A thermomagnetic energy recovery system according to Claim 1 or Claim 3, characterized in that thermal insulation material is added to the second conductive plate (22) to reduce the effect of external ambient temperatures and ensure the stabilization of the thermoelectric potential difference obtained from chimney gases.

5. A thermomagnetic energy recovery system according to claim 1 , claim 3, or claim 4, characterized in that the electrical connection terminals (24) have a modular design, allowing for the rapid detection and resolution of potential system failures and facilitating maintenance processes.

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