DESIGN, DEVELOPMENT & STUDY OF A LATENT HEAT STORAGE SYSTEM FOR THE REPLACEMENT OF COOLING TOWER FOR DG SET

AND RECOVERY OF WASTE HEAT

Manojkumar Borekar, School of Energy and Environmental Studies, Khandwa Road Campus, Devi Ahilya University, Indore 452 107, India , manojenergy@yahoo.co.in Thermal Energy Storage Laboratory, School of Energy and Environmental Studies, Khandwa Road Campus, Devi Ahilya University, Indore 452 107, India

ABSTRACT
A significant amount of heat is wasted in electricity generation, manufacturing, chemical and industrial process. Recovery and reuse of this energy through storage can be useful in conservation of energy and meeting the peak demands of power. A shell and tube type heat exchanger has been designed and fabricated for low temperature industrial waste heat recovery using phase change material. Paraffin wax (M.P. 54 C) was used as storage media due to its low cost and large-scale availability in Indian market. Experiments were performed for different mass flow rates and inlet temperature of heat transfer fluid for recovery and use of waste heat. The effect of mass flow rate on the performance of the system was studied. Calculations for overall heat transfer coefficient during charging (melting of PCM) and discharging (solidification of PCM) and heat discharging efficiency were also made. Due to poor thermal conductivity of PCM, the value of overall heat transfer coefficients was founded low.

1.

INTRODUCTION

Energy storage has great potential for providing the means for efficient use of various forms of energy being wasted in the industry, homes, and large building to use renewable energy sources, which includes solar, wind, geothermal, and tidal. In addition, energy storage systems provide efficient means for matching of power generation and demand, and the energy is recovered during low load periods and the energy is recovered during peak load periods. The storage of thermal energy as latent heat of fusion has attractive features over the sensible heat due to its high storage density and isothermal nature of storage process at melting point temp [1]. Solidliquid transformation is most commonly utilized and the energy stored could be discharged at a constant crystallization temperature. However, most of the solid phase materials usually have low thermal conductivity. Therefore, during the discharging process, as a material solidifies onto the heat transfer surface, high thermal resistance is obtained. Some experimental and theoretical studies have been made on the thermal performance of Latent Heat Thermal Energy Storage Systems. Abhat [2] suggested that fins can be used to increase the rate of heat exchange in a PCM based energy storage system. Bansal and Buddhi [3,4] developed comprehensive theoretical models for a heat exchanger with solar water heater. Buddhi et al. [5] also made experimental study of a solar collector cum storage system with Phase Change Material. Though, aforementioned efforts have been made to study the latent heat storage systems but no commercial system could be developed so far. Buddhi et. al. [6] presented the methodology to calculate the overall heat transfer coefficient during charging heat from (hot water to PCM) & discharging mode heat from (PCM to cold water). It was assumed that most of the heat transferred to PCM or transfer from PCM was at melting /solidification temperature in the form of latent heat. The objective of this paper was to study of effectiveness of the heat exchanger having PCM as storage media. A heat recovery system with PCM storage was designed, fabricated for low temperature industrial waste heat recovery. Thermal performance of this system was studied for charging and discharging process of PCM for different mass flow rates. Commercial grade Paraffin wax was used as storage media. The thermo-physical properties of commercial Grade Paraffin wax are given in Table 1.

2.

EXPERIMENTAL SETUP

To study the thermal performance of a heat recovery system with storage, a shell and finned tube type heat exchanger was designed and fabricated. Schematic diagram of the shell and tube heat exchanger is shown in figure 1. The technical specifications of the heat exchanger are given in the table 2. The used Phase Change Materials has poor thermal conductivity, to enhance the effective thermal conductivity of the system, the radial distance between the tubes was kept 3 to 4 cm. Further, each tube was having 4 longitudinal fines of 1 cm height and 400 cm in length at equal distance. The total heat transfer area of the heat exchanger was 7.9 m2. The outside of the shell was insulated with 50 mm thick glass wool to reduce the heat losses during charging and discharging process of the PCM. Shell was filled with 120 Kg commercial grades Paraffin Wax being used as Latent Heat Storage media. Type T Copper Constantan thermocouples were used for measuring the inlet & outlet temperature of HTF, for the present series of experiment water was used as HTF. HP 3852A data acquisition system was used for measurement of temperatures. A two-tank system was used for maintaining a constant pressure head for inlet water to maintain nearly constant flow rate. Heaters with thermostats were also provided in the water tanks for constant inlet water temperature during charging mode. Flowing hot water through HTF tubes started the energy-charging test, and the stored energy was extracted by passing cold water in the HTF tubes. Ambient temperature and flow rate of water coming out from the heat exchanger PCM temperatures of the heat exchanger at three axial locations (shown in figure 1) were also measured simultaneously at an interval of 15 minutes.

3.

DESIGN CALCULATION OF LATENT HEAT STORAGE FOR DG SET

DG set capacity = 500 kVA, Power generation = 500 * P.F. = 500 * 0.8 = 400 kW Let efficiency = 42% , Therefore power input = 400/0.42 = 952.38 kW But the useful power generated = 400 kW Therefore heat rejected to water = 552.38/2 = 276.19 kW = 2236734 kcal/hr But only 60% can be recovered due to the convective and conductive losses = 165.6 kW Generally temp. of water drop in latent heat storage Hx = 15 -200 c By energy balance equation Q = m * cp * (t2 t1) m = (165.6 * 860) / (1000 * 15) = 10 * 1000 kg /hr Total amount of water req.=10000 kg/hr * 3hrs = 30000 kg (DG set running hours) Therefore total amount of heat stored water = Q = m * cp* (t2 t1) Q = 30000 * 4.18 * (80 -65) = 1881000 kJ Therefore total amount of energy in water = 1782000 kJ (6 to 7 % recovery losses) By energy balance equation mwater * cpwater * twater = (mPCM * LPCM) + (mPCM * CpPCM * tPCM) 1782000 = mPCM * ( 265.9 + 2.38 * 50 ) =>Mass of PCM = 4629 kg , Let us consider capacity of each Hx be = 465 kg, Therefore total no of Hx = 10 Hx Q = (mPCM * LPCM) + (mPCM * CpPCM * tPCM) Q = 465 * (265.9 + 2.38 * 50) = 188743.5 kJ / Hx We know that the flow rate from DG set = 10000 kg/hr for 10 HX Therefore new flow rate = 10000/10 = 1000 kg /hr Rconducation = ln(0.0254 / 0.0194 )/2 50 * 1 = 8.57 * 10 - 4 C/W (negligible) 1/U = 1/hi+1/ho = 1/3092 + 1/95.56, U = 92.69 W / m2 o K (LMTD) = (Thi T(pcm)max )-(Tho T(pcm)min))/ln((Thi T(pcm)max )/ (Tho T(pcm)min)) = ((85 78) - (65 28))/ln((85 78 )/ (65 28)) = 18.01C Q=(mPCM * LPCM) +(mPCM * CpPCM * tPCM) =188743.5 kJ/ Hx Q = UAtm , A = 114 m2 If finned tubes are used let 6 fins per inch = 4mm, Length = 1 cm, Thickness = 1mm Leffective = L + t/2 = 1 + 0.05 = 1.05, ri = 1.27 m, ro = 1.27 + Leffective = 1.27 + 1.05 = 2.32 cm At/Ab = ro2 ri 2 + ro t + ri ( - t) / ri = 8.63, Ab = 2 ri L= 2 * 3.14 * 0.0127 * 1 = 0.07975, At = 0.68829 m 2 /m The length of finned =total heat transfer area required/total finned tubes area per meter, Finned tube required for heat transfer = 113.06 m 2/0.68829 m 2 /m = 165.04 m 165 m If the length of 1 tube is 4 m, Therefore no of tubes req. = 165/4 = 41.26 42

Volume required for PCM = 465/ 775 = 0.6 m3 & 20 % clearance for expansion of PCM, Vol. req. = 0.6 * 1.20= 0.72 m3 Volume of shell = R2 h, 0.72 = 3.14 * R2 * 4, R = 0.24 m, Dshell = 0.48 m total Cross sectional area of shell = (A) TUBES +(A) SHELL =42*(/4)*d2 + (/4)*D2 = 42 *( / 4) *(0.0254)2 + ((/4) * 0.482 = 0.20 m2

4.

COST ECONOMICS

Capacity = 60 m3 / hr, Exhaust fan Motor rating = 3HP, Height = 3.8 m, Diameter = 2.73 m, App. Wt. = 850 kg Installment cost of cooling tower = Rs.1,90,000/Running cost = 3 HP * 0.746 * 3hr * Rs.5 / kW = Rs.12253/year Water cost = 60 m3 / hr *3hr * 365 days * 1000 lit = Rs.65700000/yr Therefore water cost = Rs.3285000/- (evaporative losses 5%) Total cost = Installment Cost of Cooling Tower + Running Cost + Water Cost = Rs.34, 87,253/-

4.1 COSTING OF ID, FRP COOLING TOWER

4.2 COSTING OF LATENT HEAT STORAGE HEAT EXCHANGER

Mass of tubes = no of tubes * volume of tube * density of material (m)tube = 42 * (/4 *((0.0254) 2 (0.0194) 2 * 4 )) * 8000 kg/m3 = 283.73 kg Cost of tubes = 283.73 *30 = Rs.8512.15 (cost of MS @Rs.30/kg) Cost of fins for 42 tubes = 42 * 70 *4 * 3.28 (c.f.) = Rs.38,572.8 (cost of MS fins @Rs.70/kg)

Shell Cost

Volume = /4(0.52-0.482)*4 = 0.0615 m3 m = 492.60 kg Material cost = Rs.14778.05 (cost of MS @Rs.30/kg) PCM cost = 465 * 30 = 13950 (cost of PCM @ Rs.30/kg) Total installment cost of system = Rs.125309 (cost of 10 heat exchanger = Rs.1253090)

Energy cost

Q = 188743.5 * 2.778 *10 7 *1000 = 52.43 kWh Energy cost = 52.43 *365 * 5 = Rs.95690.12 (@Rs.5/kWh) Energy cost of 10 heat exchanger = Rs.956900 Simple payback period = Investment/ Saving = (Rs.34,87,253 Rs.1253090) / Rs.956900 = 2 years & 4 months

5.

EXPERIMENTAL RESULTS AND DISCUSSIONS

The first experiment was conducted with flow rate 90 Lt./hr and the inlet temperature of the hot water was kept 90-95 C. The total heat was given to the PCM by hot water was 42178 kJ in 4.5 hours. The final average temperature of the PCM was 73.6 C during the charging period. Figure 2 shows the PCM temperatures (T1,T2 & T3) and inlet and outlet water temperatures during the charging period. Initially the PCM was in solid phase and the total amount of heat required for melting the PCM was 27516 kJ. To study the discharging performance of the heat exchanger cold water passed with flow rate 90 Lt./hr to the storage unit. The total heat was withdrawn by the cold water was 28265 kJ in 7.5 hours. The last average temperature of the PCM was 48.86 C during the discharging period. Figure 3 shows the PCM temperatures (T1,T2 & T3) and inlet and outlet water temperatures during the discharging period. The heat discharging efficiency of the heat exchanger was 67.01 %. The variation of experimentally evaluated overall heat transfer coefficient and cumulated heat vs. time during charging and discharging is plotted in figure 4 & 5. It can also be noticed that values of overall heat transfer coefficient are higher for high flow rate during charging process. It can be noticed that the variation of overall heat transfer coefficient is less during charging, however, the variation is large during discharging process. The reason may be that during discharging, PCM may be having sensible heat initially. Other experiments were conducted with different flow rates and the summaries of the results are given in table 3. It can be seen from figures during charging of PCM, the temperature difference of the inlet and outlet water temperature was higher initially and remains nearly constant after that. During discharging process, it can

be noticed from figures that the temperature difference between inlet and outlet is higher in the beginning and decreases gradually towards the inlet temperature. From figures of PCM temperatures during discharging process, it can be observed that the PCM has enough heat as the temperatures are higher than the melting temperature, however, the rise in water temperature is very low. The overall heat transfer coefficient was also calculated during the charging and discharging process. The order of overall heat transfer coefficient during charging process was 9-14 W/m2 C and during discharging was 4-10 W/m2 C. It is very obvious that the overall heat transfer coefficient would be lower during discharging process than the value of the overall heat transfer coefficient during charging process, as the PCM starts solidification and behaves as insulator.

6.

CONCLUSIONS

The experimental results show the feasibility of using PCM as storage media in heat recovery systems. LHS system with PCM can be successfully used for recovery and reuse of waste heat from the DG set also replacement of the cooling tower and recovery of waste heat proves the techno-feasibility and economy of the system. Due to poor thermal conductivity of the Phase Change Materials the overall heat transfer coefficient is quite low and more fins should be provided to increase the effectiveness of the heat exchanger. Distance between tubes, fins and mass flow rates should be selected carefully in order to optimize the performance of the heat exchanger.

7.
1. 2. 3. 4. 5. 6.

REFERENCES
Abhat A., Low temperature latent heat thermal energy storage: heat storage materials. Solar Energy 1983, Vol.30(4), 313-331. Abhat A., Latent heat thermal energy storage in the temperature range 20-80 C, First Seminar on Solar Energy Storage; Thermal Storage, Trieste-Miramare, Italy (1978). Bansal N.K. and Buddhi D., Analytical Study of a Latent Heat Storage System in a Cylinder, Energy Conv. and Mgmt 1992,Vol. 33, 235-242. Bansal N.K. and Buddhi D., Performance Equations of a Collector cum Storage Using Phase Change Materials, Solar Energy 1992, 48, 185-194. Buddhi D., Kishore J. and Bansal N.K., An Experimental Study of a Solar Collector Cum Storage System with Phase Change Material, Energy options for the 90s, Tata McGraw Hill, New Delhi 1987, 51-58. D.Buddhi, Atul Sharma, Ramchandra & Amol Balpande Experimental Thermal Performance Evaluation of A Heat Exchanger Having PCM For The storage of Waste Heat, IEA, ECESIA Annex 17, Advanced thermal energy storage through phase change materials and chemical reactions feasibility studies and demonstration projects, 4th Workshop, 21-24 March 2003, Indore, India , 8-17.

Figure 1: Schematic Diagram of a Shell and Finned Tube Type Heat Exchanger with Heat Storage & two stages feed water tank.

Table 1: Thermo-physical properties of commercial grade paraffin wax used as PCM Melting temperature of the PCM *53.32 C Latent heat of fusion *184.48 k J/kg Density of the PCM (liquid phase) 775 kg/m3 Specific heat of the PCM (solid phase) 2384 J/kg C Thermal Conductivity 0.15 W/mK Viscosity 6.3 X10-3 Kinamatic Viscosity 8.31 X10-5 m2/sec Prandtal Number 1001.23 Thermal Expansion Coefficient 7.14 X 10-3 /C *Measured through Differential Scanning Calorimeter Table 2: Technical specifications of the heat Exchanger Type Shell & Tube with Longitudinal fins Shell Diameter 24.0 cm Length 400 cm Shell thickness 0.4 cm Pitch Circle Diameter 10 cm No of Tubes 19 Outer Diameter of Tube 0.8 cm Tube Thickness 0.1 cm No. of fin on each tube 4 Longitudinal Fin Height 1.0 cm Fin Thickness 0.1 cm Capacity of Shell 120 kg Material Mild Steel

Table 3.: Thermal performance of the heat exchanger Experiment No. Flow rate during charging Mode (LPH) Flow rate during discharging Mode (LPH) Energy released by the hot water during charging mode(kJ) Overall heat transfer Coefficient during charging mode (W / m2 o K) Time Interval during charging mode(Hrs.) Energy gained by the cold water during discharging mode(kJ) Time Interval during discharging mode(Hrs) Overall heat transfer Coefficient during discharging mode (W / m2 o K) Efficiency(%) Exp I 90 90 42178 13.64 4.5 28265 7.5 8.04 67.01 Exp II 60 60 42227 9.67 6.5 27511 6.75 9.43 65.15 Exp III 120 30 33608 11.28 3.0 23477 14.0 4.47 69.85

100.00 90.00 80.00

80.00 70.00 60.00 TEMP(C) 50.00 40.00 30.00 20.00 10.00 0.00 0.00, 1.00, 2.00, 3.00, 4.00, 5.00, 6.00,
4.45,
Twi Two T1 T2 T3

70.00

TEMP(C)

60.00 50.00 40.00 30.00 20.00 10.00 0.00 0:15 0:45 1.15, 1.45, 2.15, 2.45, 3.15, 3.45, 4.15,
Twi Two T1 T2 T3

TIME(HR)

TIME(HR)

Figure 2:Variation of inlet and outlet water temperature & PCM axial temperature (T1, T2 & T3) with time during charging mode with average flow rat of 90 L/hr.

Figure 3:Variation of inlet and outlet water temperature & PCM axial temperature (T1, T2 & T3) with time during discharging mode with average flow rate of 90 L/hr.

7.00,
50.00 45.00 40.00 35.00 30.00 25.00 20.00 15.00 10.00 5.00 0.00 4.45,

45000.00

CUMULATED HEAT

40000.00 35000.00 30000.00 25000.00 20000.00 15000.00 10000.00 5000.00 0.00 0:15 0:45 1.15,

CUMULATED HEAT

Accumulated Heat U52

0:15

0:45

1.15,

1.45,

2.15,

2.45,

3.15,

3.45,

1.45,

2.15,

2.45,

3.15,

3.45,

4.15,

4.45,

TIME(HR)

TIME(HR)

Figure 4:Overall heat transfer coefficient for flows rate 90 L/hr with time during charging mode

Figure 4:Overall heat transfer coefficient for flows rate 90 L/hr with time during & discharging mode

4.15,

50.00 45.00 40.00 35.00 30.00 25.00 20.00 15.00 10.00 5.00 0.00

45000 40000 35000 30000 25000 20000 15000 10000 5000 0

Accumulated Heat U52

Ucoeffcient