Metallic Melt Heat Storage for Surplus Grid Power in Galvanizing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial processes, particularly hot-dip galvanizing, rely heavily on fossil fuels for continuous heat input due to the high energy demand, which is inefficient and environmentally harmful, and the integration of renewable energy sources is hindered by fluctuating power outputs leading to surplus electricity that cannot be effectively utilized.
Innovation Solution
Utilize surplus electricity from renewable sources to thermally charge a metallic melt and/or treatment bath, which acts as an electrical heat storage medium, decoupling the charging process from the industrial process, and convert excess heat back into electrical energy for grid stability and efficient use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fossil fuels are used to provide continuous heat input for the melt, then the process temperature can be maintained reliably, but fossil fuel consumption increases and environmental harm worsens
Solution Approach 1:
The patent changes the energy source parameter from fossil fuels to surplus electricity, and changes the thermal storage medium parameter to a metallic melt. This allows the system to store thermal energy in the melt itself, maintaining process temperature reliability while eliminating fossil fuel consumption and associated environmental harm.
Solution Approach 2:
The patent converts the previously harmful surplus electricity (which caused grid instability when not utilized) into a beneficial resource for heating the melt. By utilizing what was previously wasted energy, the system achieves climate-neutral operation while maintaining reliable process temperature through the thermal mass of the melt.
2Object-generated harmful factors
If renewable energy sources are integrated into the power grid, then climate neutrality is improved, but fluctuating power output causes surplus electricity that cannot be effectively utilized
Solution Approach 1:
The patent introduces the metallic melt as an intermediary thermal storage medium between the fluctuating renewable energy source and the industrial process. The melt absorbs surplus electricity by increasing its thermal energy content, then releases this energy to maintain process temperature, effectively mediating the mismatch between intermittent supply and continuous demand.
Solution Approach 2:
The system performs preliminary thermal charging of the melt during periods when surplus electricity is available, storing energy in advance before it is needed for the industrial process. This preliminary action allows the system to prepare thermal energy ahead of time when renewable generation exceeds demand.
3Reliability
If the melt is heated continuously to maintain process temperature, then reliable process control is achieved, but energy consumption increases
Solution Approach 1:
The patent maintains continuous useful action by keeping the melt in a molten state with inherent thermal mass, which continuously provides heat to the industrial process without requiring active heating. The thermal energy stored in the melt acts continuously to maintain process temperature, eliminating the need for continuous energy input while preserving reliable process control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances the use of renewable energy, reduces fossil fuel consumption, stabilizes the power grid, and contributes to decarbonization by providing a sustainable heat source for industrial processes while managing fluctuating energy supplies.
Implementation Method 1
the extracted surplus electricity is used to thermally charge and/or heat at least one melt (2), in particular a metal melt
Implementation Method 2
the heated melt (2) is held and/or provided both as an electrical heat storage medium and for processing in an industrial production process
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a plant for operating an industrial process using a melt, preferably in a hot-dip galvanizing process for iron or steel components, and its use.