Waste Heat Recovery via Direct Mechanical Coupling
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Solution Overview
Problem
The low attractiveness of feeding generated electricity into the grid due to low electricity procurement costs, high EEG surcharges, and costly administrative efforts for calibrated meters in industrial settings makes it uneconomical to utilize waste heat for energy generation through thermodynamic cycles like the Organic Rankine Cycle (ORC).
Innovation Solution
A system that utilizes waste heat from industrial plants to power a thermodynamic cycle device, such as an ORC, to generate mechanical or electrical energy, which is then used directly within the industrial plant to drive components like pumps, air compressors, or fans, eliminating the need for grid feed-in and reducing infrastructure costs by using energy storage and clutch mechanisms to manage energy distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If waste heat is converted to electricity and fed into the grid, then energy recovery is achieved, but high administrative costs and EEG surcharges reduce economic attractiveness
Solution Approach 1:
The invention extracts the electricity generation function from the overall system and replaces it with direct mechanical coupling. The expansion machine is mechanically coupled to driven components, eliminating the need for grid connection, calibrated meters, and complex billing procedures while maintaining waste heat to useful energy conversion
Solution Approach 2:
The system serves itself by directly utilizing the generated mechanical energy to drive components within the same industrial plant. The expansion machine mechanically drives pumps, compressors, or other components without external grid involvement, eliminating administrative overhead and EEG surcharges
2Loss of energy
If electricity is generated and fed into the grid, then energy recovery is achieved, but low electricity procurement costs and EEG surcharges make it uneconomical
Solution Approach 1:
The system uses the generated energy to serve itself by directly driving components within the plant. The mechanical energy from the expansion machine powers pumps, compressors, or other driven components, eliminating the need to sell electricity at low grid prices and avoiding EEG surcharges
Solution Approach 2:
The invention merges the energy generation and energy consumption functions within the same industrial plant. The expansion machine and driven components are integrated into a single mechanical energy transfer system, allowing direct utilization of recovered energy without external grid transactions
3Device complexity
If direct mechanical coupling is used to drive components, then infrastructure costs are reduced, but energy distribution control becomes more complex
Solution Approach 1:
The invention employs dynamic coupling mechanisms that can be engaged or disengaged as needed. The mechanical coupling between the expansion machine and driven components can be dynamically adjusted or disconnected, providing operational flexibility without requiring complex permanent infrastructure
Solution Approach 2:
The patent introduces an intermediary electric motor/generator unit between the expansion machine and driven components. This intermediary provides decoupling flexibility, allowing the system to operate in different modes (direct mechanical drive, electrical drive, or energy storage) while simplifying overall 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 approach allows for the economical use of waste heat within the industrial plant, reducing the need for grid connection and administrative efforts, saving components and infrastructure costs, while providing a stable energy source through direct utilization of generated energy.
Implementation Method 1
a thermodynamic cycle device, in particular an ORC device, with a heat exchanger for transferring heat from the heat source to a working medium of the thermodynamic cycle device
Implementation Method 2
an expansion device for expanding the working medium and for generating mechanical or electrical energy
Data Source
AI summary
The invention relates to a system for energy recovery within an arrangement of industrial components. The system comprises a heat source of the arrangement; a thermodynamic cycle device, in particular an ORC device, with a heat exchanger for transferring heat from the heat source to a working medium of the thermodynamic cycle device and with an expansion device for expanding the working medium and for generating mechanical or electrical energy; and at least one driveable component of the arrangement, in particular at least one hydraulic or pneumatic machine that can be driven by the generated energy. The invention further relates to a corresponding method for energy recovery within an arrangement of industrial components.