WO2025078187A1 - Système de récupération de chaleur perdue pour la production de vapeur industrielle - Google Patents
Système de récupération de chaleur perdue pour la production de vapeur industrielle Download PDFInfo
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- WO2025078187A1 WO2025078187A1 PCT/EP2024/077414 EP2024077414W WO2025078187A1 WO 2025078187 A1 WO2025078187 A1 WO 2025078187A1 EP 2024077414 W EP2024077414 W EP 2024077414W WO 2025078187 A1 WO2025078187 A1 WO 2025078187A1
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- heat
- transfer fluid
- heat transfer
- storage unit
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K3/00—Plants characterised by the use of steam or heat accumulators, or intermediate steam heaters, therein
- F01K3/006—Accumulators and steam compressors
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K23/00—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids
- F01K23/02—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled
- F01K23/06—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle
- F01K23/064—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle in combination with an industrial process, e.g. chemical, metallurgical
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K3/00—Plants characterised by the use of steam or heat accumulators, or intermediate steam heaters, therein
- F01K3/08—Use of accumulators and the plant being specially adapted for a specific use
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K3/00—Plants characterised by the use of steam or heat accumulators, or intermediate steam heaters, therein
- F01K3/12—Plants characterised by the use of steam or heat accumulators, or intermediate steam heaters, therein having two or more accumulators
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F22—STEAM GENERATION
- F22B—METHODS OF STEAM GENERATION; STEAM BOILERS
- F22B1/00—Methods of steam generation characterised by form of heating method
- F22B1/02—Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers
- F22B1/028—Steam generation using heat accumulators
Definitions
- the invention relates to a waste heat recovery system for generating steam for chemical industrial plants, comprising a discontinuously operable chemical industrial plant with at least one coolable reactor connected to a primary circuit, wherein the at least one reactor is designed such that a reaction of a reaction mixture takes place during operation of the reactor and the waste heat generated by the cooling of the reactor flows through the primary circuit either in the form of a heated liquid or in the form of the reaction mixture itself as the first heat transfer fluid, wherein the primary circuit fluidically connects the reactor to a first heat exchanger such that the first heat transfer fluid is cooled in the first heat exchanger and is then returned to the reactor to cool the reactor.
- waste heat recovery systems can improve the efficiency of chemical processes.
- discontinuous processes or even in continuous processes that require frequent interruptions, for example, for maintenance, the general problem is that waste heat cannot be recovered during the interruption.
- Heat storage systems can at least bridge a certain interruption period.
- the integration of a heat storage system is very complex and can be implemented significantly differently depending on the specific application.
- KR-2015-0032241 A discloses a waste heat recovery system that uses intermittently generated waste heat from a batch reactor to generate steam on demand.
- the system contains a heat transfer fluid in a circuit that cools the reactor and releases the heat absorbed by the reactor through heat transfer.
- the heat transfer takes place either through a heat exchanger that heats another heat transfer fluid, which is then fed to a flash tank for steam generation, or through heat transfer that takes place directly in the water level of the flash tank.
- a steam accumulator serving as a heat storage device, is installed downstream of the flash tank steam outlet to ensure continued steam availability in the event of a reactor shutdown.
- this implementation has the disadvantage that the steam occupies a large volume relative to its energy content, and the steam accumulator must be correspondingly large. Furthermore, the steam accumulator must also be able to withstand the steam pressure.
- US 2010/0319348 A1 discloses a waste heat recovery system belonging to another technical field, in which hot waste fluids of a combustion furnace, such as Flue gases flow through a heat exchanger, which is configured to transfer energy in the form of heat to a heat transfer fluid. The energy in the heat transfer fluid is used to generate electrical energy.
- this implementation has the limitation that only the energy from hot waste fluids is recovered in the form of usable electricity.
- the waste fluid cooled by a heat exchanger is not reused in the current process.
- the disadvantage of this process is that the cooled waste fluid is not reused.
- the task therefore arose to provide a waste heat recovery system for generating steam for chemical industrial plants.
- the waste heat extracted for cooling a discontinuously operated reactor also serves to generate steam, allowing steam to continue to be generated continuously even during reactor interruptions.
- Another challenge is to ensure efficient and stable operation of the waste heat recovery system.
- the evaporator unit is designed so that steam is generated during operation of the waste heat recovery system and is preferably fed to at least one compressor.
- the compressed steam is preferably made available to an industrial plant and/or a steam network.
- the waste heat recovery system according to the invention has the advantage that the waste heat extracted for cooling the at least one discontinuously operated reactor enables the continuous generation of industrial steam. Thus, industrial steam continues to be generated continuously even during interruptions in reactor operation.
- the secondary circuit with the two heat storage units ensures efficient and stable operation of both the at least one reactor and the continuous industrial steam generation.
- heat exchanger is defined as a device that can transfer heat from one fluid to another. Examples include plate heat exchangers or shell-and-tube heat exchangers.
- a "primary circuit" in this document represents a circuit flow in which a reactor is fluidically connected to a first heat exchanger in such a way that a first heat transfer fluid is cooled in the first heat exchanger and then returned to the reactor to cool the reactor.
- the primary circuit can also contain branches, for example, as a bypass connected in parallel to the reactor.
- Several reactors can also be in the Primary circuit may be present, for example in an arrangement of parallel circuits, series circuits or combinations of parallel and series circuits.
- a "secondary circuit" in this document represents a circuit flow in which a first heat exchanger is coupled to a secondary circuit in such a way that, during operation of the at least one reactor, a second heat transfer fluid is heated by a first heat transfer fluid, and the secondary circuit, starting from the first heat exchanger, fluidically connects a downstream first heat storage unit, an evaporator unit downstream of the first heat storage unit, a second heat storage unit downstream of the evaporator unit and the first heat exchanger downstream of the second heat storage unit, thereby closing the secondary circuit.
- the second heat transfer fluid is also pumped from the first heat storage unit to the second heat storage unit, allowing the evaporator unit to continue operating and thus continue to generate steam continuously.
- the mass flow of the second heat transfer fluid from the second heat storage unit to the first heat storage unit is stopped.
- a cooler can be arranged between the second heat storage unit and the first heat exchanger to cool the second heat transfer fluid.
- the secondary circuit may also contain branches, such as a bypass parallel to the evaporator unit.
- Multiple evaporator units may also be present in the secondary circuit, for example, in a parallel circuit, series circuit, or combination of parallel and series circuits.
- an "evaporator unit” represents a heat exchanger unit or a flash tank unit. If the evaporator is a heat exchanger unit, a heat exchanger of the heat exchanger unit transfers a heat flow from its primary side to its secondary side, causing, for example, water supplied to the secondary side to at least partially evaporate. In the case of a heat pump circuit connected to the secondary side, the working fluid in the heat pump circuit evaporates accordingly.
- the evaporator unit can also contain other standard components, such as control valves, pressure reducers, flow regulators, or sensors.
- the evaporator unit can therefore also include a control system.
- the term “evaporator unit” can also refer to multiple evaporators connected in series or parallel.
- Suitable heat exchangers as evaporators are thin-film, Robert, falling-film, natural circulation, and forced circulation evaporators. These evaporators can be designed as shell-and-tube heat exchangers or plate heat exchangers. Suitable Evaporators are known and described, among others, in: SPX, Evaporator Handbook, APV Americas, Engineered Systems, Separation Technologies, 4th edition, available at htps://userpages.umbc.edu/ ⁇ dfrey1/ench445/apy evap.pdf (accessed on May 20, 2022).
- a “flash tank unit” represents one possible form of evaporator unit in this document.
- the flash tank unit has a tank, which preferably contains an expansion nozzle in the upper region. If an expansion nozzle is present, a fluid is fed to the flash tank through the inlet of the expansion nozzle. If no expansion nozzle is present, the fluid is fed to the flash tank through a flash tank supply line, which preferably leads into the flash tank.
- the fluid not vaporized in the flash tank collects in the lower region of the flash tank and is discharged through a flash tank outlet. The vaporized fluid is discharged through a vapor outlet in the upper region of the flash tank.
- a "heat storage unit” includes a thermal energy storage device as a heat storage device, the outer walls of which may be insulated.
- the heat storage device has an inlet in the upper area, preferably at the uppermost point of the tank, and an outlet in the lower area, preferably at the lowest point of the tank.
- the heat storage unit may also contain other standard components, such as control valves, pressure reducers, level sensors, flow controllers, or sensors.
- a heat storage heating element can also be arranged inside or on the outer wall of the heat storage tank to heat up the fluid in the tank if the temperature is too low.
- the heat storage unit can therefore also include a control system.
- the term “heat storage unit” can also refer to multiple heat storage units connected in series or parallel.
- the fluid is a liquid such as water, thermal oil, or molten salt. It is also possible for the fluid to be a gas such as air or CO2.
- a "temperature controller” refers to a controller that measures the temperature at its mounting location using a temperature sensor associated with the controller. Typically, it is a PID controller.
- a “flow controller” refers to a controller that measures the flow rate at the location of its installation using a flow sensor associated with the controller. Typically, it is a PID controller.
- a “load controller” in this document represents a controller that determines the load at least by means of a flow sensor and a temperature sensor, whereby the load corresponds to the transferred heat flow, i.e. the transferred energy per time, whereby the transferred heat flow is the product: mass flow of a heat transfer fluid * Heat capacity C p of the heat transfer fluid * (temperature of the heat transfer fluid before heat transfer minus the temperature of the heat transfer fluid after heat transfer).
- the heat capacity C p of the heat transfer fluid is preferably considered as a simplified constant and, in this preferred case, does not need to be determined separately by a sensor or by mathematical models.
- the heat capacity CP of the heat transfer fluid may be represented by a function of temperature, such as the function that averages the inlet and outlet temperatures of a heat exchanger.
- the load controller is a PID controller.
- the first heat transfer fluid can be the reaction mixture from the reactor or another fluid.
- the reaction mixture from the reactor is also referred to as the product stream.
- the following fluids are preferably used as the second heat transfer fluid:
- cold fluid in this document means that the corresponding fluid does not fall below a predetermined minimum temperature in the stratified storage tank and that the temperature of the fluid only exceeds the minimum temperature by a maximum of half the difference between the predetermined maximum temperature of the fluid in the stratified storage tank and the predetermined minimum temperature of the fluid in the stratified storage tank.
- warm fluid in this document means that the corresponding fluid does not exceed a predetermined maximum temperature in the stratified storage tank and that the temperature of the fluid only falls below the maximum temperature by a maximum of half the difference between the predetermined maximum temperature of the fluid in the stratified storage tank and the predetermined minimum temperature of the fluid in the stratified storage tank.
- the at least one reactor has at least one cooling element, which preferably comprises at least one built-in cooling coil, a built-in pipe register and/or a comprises a heat exchanger arranged outside or inside the at least one reactor, and wherein the at least one cooling element is fluidically connected to the primary circuit and configured such that the first heat transfer fluid flows through the at least one cooling element during operation of the industrial plant.
- at least one cooling element which preferably comprises at least one built-in cooling coil, a built-in pipe register and/or a comprises a heat exchanger arranged outside or inside the at least one reactor, and wherein the at least one cooling element is fluidically connected to the primary circuit and configured such that the first heat transfer fluid flows through the at least one cooling element during operation of the industrial plant.
- the second heat transfer fluid is water, preferably demineralized water
- the first heat transfer fluid is also water, preferably demineralized water
- the second heat transfer fluid is water, preferably demineralized water
- the first heat transfer fluid is the reaction mixture
- the second heat transfer fluid is water and the evaporator unit is a flash tank unit which has an inlet for filling the flash tank with the second heat transfer fluid, an inlet for filling the flash tank with water, preferably demineralized water, a water outlet for discharging water to the second heat storage unit, a steam outlet and an expansion nozzle which is designed such that during operation of the waste heat recovery system an expansion steam is generated as water vapor and this is fed through the steam outlet to the at least one compressor.
- the evaporator unit is a heat exchanger unit having an inlet and outlet for the second heat transfer fluid to flow through, an inlet for water to flow through, and a steam outlet, wherein the heat exchanger unit is designed such that during operation of the waste heat recovery system, the water is evaporated in the heat exchanger unit and is fed to the at least one compressor through the steam outlet.
- more than one reactor is present and the reactors are connected in parallel to each other and each reactor has its own heat exchanger, each heat exchanger being thermally connected to the secondary circuit.
- a vertically arranged stratified storage tank replaces the first and second heat storage units, wherein the inlet for the second heat transfer fluid originating from the first heat exchanger is arranged in the upper region of the stratified storage tank, preferably at the very top, and wherein the inlet for the second heat transfer fluid originating from the evaporator unit is arranged in the lower region of the stratified storage tank.
- the stratified storage tank preferably has the outlet to the first heat exchanger in the lower section of the stratified storage tank, and particularly preferably at the very bottom. Furthermore, the stratified storage tank preferably has the outlet to the evaporator unit in the upper section of the stratified storage tank.
- the term “at the very top” in this document is to be understood as meaning the uppermost point of the stratified storage tank.
- the term “at the very bottom” in this document is to be understood as meaning the lowest point of the stratified storage tank.
- the term “in the upper area” in this document is to be understood as meaning a point of the stratified storage tank that is at a height of the stratified storage tank in the range of 75 to 100% of the maximum height of the stratified storage tank.
- the term “in the lower area” in this document is to be understood as meaning a point of the stratified storage tank that is at a height of the stratified storage tank in the range of 0 to 25% of the maximum height of the stratified storage tank.
- the evaporator unit represents a heat exchanger.
- a closed heat pump circuit is fluidically connected to the secondary side of this heat exchanger.
- This circuit contains a compressor, a Joule-Thomson valve, or a turbine, as well as another heat exchanger.
- a turbine can also generate mechanical energy or electrical power.
- the working fluid for the closed heat pump circuit can, for example, be Water and/or a synthetic fluid may be used.
- Organic fluids, such as pentane or heptane, are also generally suitable as working fluids for the closed heat pump circuit.
- a hydrocarbon fluid is preferably used as the working fluid for the closed heat pump circuit.
- Ammonia is particularly preferred as the working fluid for the closed heat pump circuit.
- Another subject of the invention is the method for operating the waste heat recovery system.
- the method according to the invention for operating a waste heat recovery system for generating steam for chemical industrial plants contains
- a discontinuously operable chemical industrial plant having at least one coolable reactor, wherein the at least one reactor is designed such that a reaction of a reaction mixture takes place during operation of the reactor and the waste heat generated by cooling the reactor flows either in the form of a heated liquid or in the form of the reaction mixture itself as the first heat transfer fluid through a primary circuit, wherein the primary circuit fluidically connects the reactor to a first heat exchanger such that the first heat transfer fluid is cooled in the first heat exchanger and then returned to the reactor to cool the reactor,
- a secondary circuit containing a separate second heat transfer fluid which is thermally coupled to the first heat exchanger such that during operation of the at least one reactor the second heat transfer fluid is heated by the first heat transfer fluid
- the secondary circuit starting from the first heat exchanger, fluidically connects a downstream first heat storage unit, an evaporator unit downstream of the first heat storage unit, a second heat storage unit downstream of the evaporator unit and the first heat exchanger downstream of the second heat storage unit, whereby the secondary circuit is closed.
- the method according to the invention comprises the following steps when one reactor is out of operation or, in the case of several reactors, all reactors are out of operation:
- This inventive method offers the advantage that the waste heat extracted for cooling the at least one discontinuously operated reactor enables the continuous generation of industrial steam.
- industrial steam continues to be generated continuously even during interruptions in reactor operation.
- the secondary circuit with the two heat storage units ensures efficient and stable operation of both the at least one reactor and the continuous industrial steam generation.
- the temperature of the second heat transfer fluid at the inlet of the first heat storage unit is adjusted by a first temperature controller with its associated temperature sensor in conjunction with a first flow controller with its associated flow sensor arranged between the second and first heat storage unit in the main flow direction, in that the first temperature controller determines a difference between a predetermined setpoint value and the temperature of the second heat transfer fluid at the inlet of the first heat storage unit detected by the first temperature controller, and in that the first temperature controller transmits a setpoint value to the first flow controller on the basis of the determined difference, and the first flow controller adjusts the flow from the second to the first heat storage unit as a function of this setpoint value and the measured flow from the second to the first heat storage unit.
- the predetermined setpoint usually corresponds to the desired temperature value of the first heat storage unit.
- a first level controller with its associated level sensor of the first heat storage unit serves as the higher-level controller. If the level sensor detects a value that exceeds a predetermined maximum level value of the first heat storage unit, the second primary circuit valve closes and the first primary circuit valve opens to cool the mass flow of the reaction mixture conveyed out of the reactor in the process heat exchanger. In this case, the mass flow of the reaction mixture conveyed out of the reactor is not passed through the first heat exchanger.
- a load controller calculates with its associated sensors, which include a flow sensor in the line after the evaporator unit and/or in the line before the evaporator unit, a temperature sensor in the line after the evaporator unit and a temperature sensor for detecting the temperature before the evaporator unit, The heat flow difference between the heat flow of the second heat transfer fluid in the line downstream of the evaporator unit and the heat flow of the second heat transfer fluid in the line upstream of the evaporator unit. The difference between the measured heat flow difference and a specified load setpoint results in a setpoint. This setpoint is passed to a third flow controller as a slave controller with its associated flow sensor.
- the second secondary circuit valve is controlled, whereby the flow of the second heat transfer fluid in the line after the evaporator unit is adjusted accordingly.
- the predetermined load setpoint is determined by a second fill level controller arranged in the first heat storage unit with its associated fill level sensor.
- the second fill level controller represents a master controller and is preferably a P controller.
- the second fill level controller calculates the difference between the fill level of the first heat storage unit and a predetermined setpoint of the fill level. Based on this difference, a load setpoint is determined and transmitted to the load controller.
- the fill level of the first heat storage unit serves as a predefined load setpoint, thus influencing the heat flow for steam generation. If the fill level is low, the heat flow would be lower to prevent the first heat storage unit from running dry. And if the fill level is high, the heat flow would be correspondingly higher to prevent the first heat storage unit from filling up.
- the second level controller continuously detects level values in the first heat storage unit.
- the load setpoint for the load controller is determined based on the detected level value, with the detected level value being limited to the range from a predetermined minimum level value to a predetermined maximum level value.
- the advantage of this design is that it is easier to implement in a process control system.
- the disadvantage is that the setpoint for the heat flow difference contains all values between the "maximum steam generation” mode and the "minimum steam generation” mode. This is a continuous control.
- the advantage of this design is that the load controller UC essentially operates either in "minimum steam generation” or “maximum steam generation” mode, and not in between. This is a discontinuous control.
- This discontinuous control is advantageous for the compressor because it does not have to constantly change its operating mode.
- the at least one reactor is a batch reactor. This offers the advantage that the heat recovery system can be operated efficiently, since the downtimes of the batch reactor allow for optimal utilization of the heat storage units.
- the first and second heat storage units are combined to form a vertically arranged stratified storage unit, such as shown in Fig. 5, wherein the inlet for the second heat transfer fluid, which originates from the first heat exchanger, is located in the upper region of the stratified storage unit, preferably at the very top of the stratified storage unit. is arranged, and wherein the inlet for the second heat transfer fluid originating from the evaporator unit is arranged in the lower region of the stratified storage tank, preferably at the very bottom of the stratified storage tank.
- a preferred control concept when using a stratified storage tank is discrete switching depending on the temperature profile of the liquid in the stratified storage tank.
- the control system comprises at least four temperature sensors arranged along the height of the stratified storage tank as shown in Fig. 5. Depending on the temperatures measured at these positions, discrete switching should take place between the states “No recovery” and “Min recovery”, and between “Min recovery” and “Max recovery”.
- the compressor which compresses the water vapor generated by the evaporator unit, is operated depending on the discrete states: “No recovery”, “Min recovery”, and “Max recovery”. Thus, the compressor is operated at maximum load when the value "Max recovery” is present. If the value "No recovery”, the compressor is switched off. If the value "Min recovery” is present, the compressor is operated at full load with a load in the range of 30 to 90%, preferably in the range of 60 to 80%.
- the setpoint for the controller UC is also determined based on this discrete control logic.
- the discrete states can be determined, for example, as follows:
- the temperature sensors T1, T2, T5 and T6 are arranged in the stratified storage tank from top to bottom along the height of the stratified storage tank.
- the stratified storage tank is filled with cold fluid and the discrete state is set to "No recovery.” If the temperature of temperature sensor T2 is greater than a predetermined value T1, the discrete state is set to "Min recovery.” If, starting from the "Min recovery” state, the temperature of temperature sensor T1 is less than a predetermined value T1, the discrete state is set from "Min recovery” to "No recovery.”
- the control system when using a stratified storage tank, includes an additional QC controller that protects the waste heat recovery system from overload.
- the additional QC controller preferably replaces the LC level controllers used for the variant with two heat storage units.
- This additional controller QC can, for example, act as a soft sensor and determine a scalar value as the actual value from the profile of the density of the liquid and/or the temperature of the liquid in the stratified storage tank along the height of the stratified storage tank. Based on the difference between the actual value and a predetermined setpoint, the valve in the inlet to the first heat exchanger and the valve in the inlet to the process heat exchanger are then adjusted as shown in Fig. 5.
- the additional controller QC can also control another physical property instead of the density, whereby the physical property is preferably dependent on the temperature.
- the control is preferably based on a scalar value, which is preferably determined by a soft sensor.
- the soft sensor can take temperatures and/or other measurements into account when determining the scalar value.
- Various measurement techniques can be used to determine density, such as electrical capacitance measurement, which measures the average density in the stratified storage tank by installing an electrode along the height of the stratified storage tank.
- the average density is preferably based on volume-related averaging.
- density measurement based on ultrasonic measurement methods is also suitable.
- the amount of cold and hot fluid in the stratified storage tank is calculated on the basis of the densities determined over the height of the stratified storage tank.
- the density of the fluid over the entire height of the stratified storage tank essentially corresponds to the maximum permissible temperature of the fluid and thus the entire volume of the stratified storage tank is essentially filled with hot fluid, this means that the stratified storage tank has reached its maximum storage capacity.
- the density indirectly provides information about the amount of hot fluid in the stratified storage tank. It also indicates the extent to which the stratified storage tank's maximum storage capacity has been reached and the amount of steam the heat recovery system can generate.
- the compressor preferably operates with "Max Recovery" when the maximum storage capacity of the stratified storage tank has already been reached.
- the first heat exchanger preferably receives less flow of the first heat transfer fluid.
- more than one reactor is present, and the reactors are connected in parallel.
- Each reactor has its own heat exchanger, with each heat exchanger being thermally connected to the secondary circuit.
- Second primary circuit valve for adjusting the mass flow j
- First heat exchanger for heating the incoming mass flow I by the mass flow j
- UC load controller with its associated temperature and flow sensor, represented by U1.
- the first embodiment of the waste heat recovery system according to the invention for generating steam for chemical industrial plants comprises a coolable batch reactor 2 connected to a primary circuit.
- the batch reactor 2 is designed such that an exothermic reaction of the reaction mixture takes place during operation of the batch reactor 2.
- the two reactant mass streams a and b are mixed by a mixer 1 before being fed to the batch reactor 2.
- a further reactant stream c can also be fed to the batch reactor through a further feed line and a further inlet.
- the reaction mixture itself flows as the first heat transfer fluid through the primary circuit, driven by a primary circuit pump 4.
- the primary circuit fluidically connects the batch reactor 2 to a first heat exchanger 9 through lines d and j such that the first heat transfer fluid is cooled in the first heat exchanger 9 and then returned to the mixer 1 through line i to cool the batch reactor 2.
- the flow rate of the reaction mixture from the system can be adjusted by valve 5.
- a first primary circuit valve 6 is used to regulate the mass flow of the first heat transfer fluid at the inlet of the supply line f to a process heat exchanger 7.
- the control is carried out based on a first level controller with an associated level sensor L1_1 of a first heat storage unit 10.
- the control calculates a difference between the currently measured level and a predetermined value.
- the first primary circuit valve 6 is then adjusted based on this difference. The goal is to recover as much reaction heat as possible. This means that the primary circuit valve 6 should generally be closed, and a second primary circuit valve 8 in the supply line j should generally be open.
- the second primary circuit valve 8 generally serves to regulate the mass flow of the first heat transfer fluid to the first heat exchanger 9.
- the first fill level controller with its associated fill level sensor L1_1 throttles the valve 8 and opens the valve 6, so that at least part of the product stream d is cooled in the process heat exchanger 7 without flowing through the first heat exchanger 9.
- the process heat exchanger 7 can temper the first heat transfer fluid coming from the supply lines f and k. The tempered first heat transfer fluid is then added to the mixer 1 through line i. The cooling or heating medium for the process heat exchanger 7 is supplied to the process heat exchanger 7 through the supply line g and is discharged from the process heat exchanger 7 through the line h.
- the process heat exchanger 7 When the heat recovery system is in operation, the process heat exchanger 7 is typically in standby mode. In this case, the process heat exchanger 7 does not cool the first heat transfer fluid, even though the first heat transfer fluid continues to flow through it. Instead, the cooling of the first heat transfer fluid takes place in the first heat exchanger 9.
- a separate secondary circuit contains a second heat transfer fluid, which is coupled to the first heat exchanger 9 such that the second heat transfer fluid is heated by the first heat transfer fluid during operation of the batch reactor 2.
- the second heat transfer fluid flows through line I into the first heat exchanger 9, where it is heated by the first heat transfer fluid on the primary circuit side of the first heat exchanger 9 and is then fed to the first heat storage unit 10 via the supply line m.
- the secondary circuit fluidically connects, starting from the first heat exchanger 9, the downstream first heat storage unit 10 via supply line m, a heat exchanger unit 13 downstream of the first heat storage unit 10 via line n, a second heat storage unit 14 downstream of the heat exchanger unit 13 via line o, and the first heat exchanger 9 downstream of the second heat storage unit 14 via line I, thereby closing the secondary circuit.
- a first secondary circuit pump 11 conveys the second heat transfer fluid from the first heat storage unit through line n to the heat exchanger unit 13.
- a second secondary circuit pump 15 conveys the second heat transfer fluid from the second heat storage unit 14 through line I to the first heat exchanger 9.
- a first secondary circuit valve 16 serves to regulate the mass flow in the supply line I to the first heat exchanger 9, wherein the control is carried out on the basis of a first temperature controller as a master controller with its associated temperature sensor T3, which detects the temperature of the second heat transfer fluid in the supply line m, and a first flow controller as a slave controller with its associated flow sensor F1, which detects the mass flow of the second heat transfer fluid in the supply line m.
- a difference between the currently measured temperature of the second heat transfer fluid in the supply line m and a predetermined setpoint is calculated.
- a setpoint for the slave controller is then transmitted to the first flow controller, whereby the first flow controller calculates the difference between the currently measured mass flow of the second heat transfer fluid in the supply line m and the setpoint determined by the master controller.
- the first secondary circuit valve 16 is controlled accordingly.
- the heat exchanger unit 13 is designed such that, during operation of the waste heat recovery system, water vapor is generated by the desalinated water s supplied via line p. This water vapor is fed through line q to a compressor 18 and thereby compressed. The mass flow of the compressed water vapor r is then discharged from the system.
- a valve 17 with a second flow controller and its associated flow sensor F3 serves to adjust the mass flow of the demineralized water s in the supply line p to the heat exchanger unit 13, wherein the control is carried out on the basis of a second temperature controller with its associated temperature sensor T4, which detects the temperature of the mass flow of the second heat transfer fluid in the line o.
- a difference between the detected temperature T4 of the second heat transfer fluid in the line o is calculated, whereby a setpoint is calculated based on this difference.
- the second flow controller with its associated flow sensor F3, is supplied with the setpoint, with the second flow controller acting as a slave controller.
- the second flow controller calculates a difference between the flow of the demineralized water s in the line p and the setpoint supplied to it, whereby the valve 17 adjusts the mass flow of the demineralized water s in the line p based on the calculated difference.
- a load controller UC with its associated sensors which include the mass flow sensor F2 and the temperature sensors T4 and T1, detects the difference between the heat flow of the second heat transfer fluid in line o and the heat flow of the second heat transfer fluid in line n, and from this calculates a difference between the detected heat flow difference and a predetermined load setpoint. Based on this difference, a setpoint is determined and passed to a third flow controller as a slave controller with its associated mass flow sensor F2. Based on the difference to be calculated by the slave controller between the mass flow of the second heat transfer fluid in line o and the setpoint determined by the load controller UC, the second secondary circuit valve 12 is controlled and the mass flow of the second heat transfer fluid in line o is thus adjusted.
- the predetermined load setpoint for the heat flow difference is determined by a second fill level controller arranged in the first heat storage unit 10 with its associated fill level sensor L1_2, wherein the second fill level controller represents a master controller and is preferably a P controller.
- the second fill level controller calculates the difference between the fill level of the first heat storage unit 10 and a predetermined setpoint. Based on this difference, a setpoint for the load controller UC is calculated and transmitted to the load controller UC.
- the second level controller with its associated level controller L1_2 can detect continuous level values in the first heat storage unit 10 and, depending on the detected level value, determine the load setpoint for the load controller UC, wherein the detected level value is limited to the range from a predetermined minimum level value to a predetermined maximum level value.
- the predetermined load setpoint for the heat flow difference is determined based on the fill level in the first heat storage unit 10, whereby the setpoint can only switch between the "maximum steam generation” mode and the "minimum steam generation” mode.
- the "maximum steam generation” mode means that the fill level in the heat storage unit 10 exceeds a first predetermined reaches or exceeds a specified value
- the "minimal steam generation” mode means that the filling level in the heat storage unit 10 both exceeds a second specified value and does not reach the first specified value.
- the heat recovery system is switched off and no more steam is generated.
- the advantage of the first embodiment is that it is easier to implement in a process control system.
- the disadvantage is that the setpoint for the heat flow difference can take on any value between the "maximum steam generation” and “minimum steam generation” modes. This represents continuous control.
- a valve 17 with the second flow controller and its associated flow sensor F3 is used to adjust the mass flow of the demineralized water s in the supply line p to the heat exchanger unit 13, whereby the control is based on the second temperature controller with its associated temperature sensor T4, which measures the temperature of the mass flow of the second heat transfer fluid in the line o.
- a difference between the detected temperature T4 of the second heat transfer fluid in the line o is calculated.
- a setpoint is calculated and transmitted to the second flow controller with its associated flow sensor F3, with the second flow controller acting as a slave controller.
- the second flow controller calculates a difference between the flow of the demineralized water s in the line p and the setpoint transmitted to it, whereby the valve 17 adjusts the mass flow of the demineralized water s in the line p based on the calculated difference.
- Fig. 2 shows a schematic process flow diagram of a waste heat recovery system and its process engineering process according to a second embodiment of the waste heat recovery system according to the invention and a second embodiment of its process according to the invention.
- the second embodiment of the waste heat recovery system for generating steam for chemical industrial plants comprises a coolable batch reactor 2 which is connected to a primary circuit, wherein the batch reactor 2 is is designed so that an exothermic reaction of the reaction mixture takes place during operation of the batch reactor 2.
- the two reactant mass streams a and b are mixed by a mixer 1 before being fed to the batch reactor 2.
- a further reactant stream c can also be fed to the batch reactor through a further feed line and a further inlet.
- the reaction mixture itself flows as the first heat transfer fluid through the primary circuit, driven by a primary circuit pump 4.
- the primary circuit fluidically connects the batch reactor 2 to a first heat exchanger 9 through lines d and j such that the first heat transfer fluid is cooled in the first heat exchanger 9 and then returned to the mixer 1 through line i to cool the batch reactor 2.
- the flow rate of the reaction mixture from the system can be adjusted by valve 5.
- a first primary circuit valve 6 is used to regulate the mass flow of the first heat transfer fluid at the inlet of the supply line f to a process heat exchanger 7, wherein the control is carried out on the basis of a first level controller with an associated level sensor L1_1 of a first heat storage unit 10.
- a difference between the currently measured level and a predetermined value is calculated, and the first primary circuit valve 6 is then adjusted based on this difference.
- the process heat exchanger 7 can temper the first heat transfer fluid coming from the supply lines f and k. The tempered first heat transfer fluid is then added to the mixer 1 through line i. The cooling or heating medium for the process heat exchanger 7 is supplied to the process heat exchanger 7 through the supply line g and is discharged from the process heat exchanger 7 through the line h.
- the second embodiment of the method according to the invention for operating a waste heat recovery system according to the above-described waste heat recovery system according to Fig. 2 comprises the following steps when the at least one reactor 2 is in operation:
- a first primary circuit valve 6 is used to regulate the mass flow of the first heat transfer fluid at the inlet of the supply line f to a process heat exchanger 7, wherein the control is carried out on the basis of a first level controller with an associated level sensor L1_1 of a first heat storage unit 10.
- a difference between the currently measured level and a predetermined value is calculated during the control, and the first primary circuit valve 6 is then adjusted based on this difference. The goal is to recover as much reaction heat as possible.
- the primary circuit valve 6 is generally preferred closed and a second primary circuit valve 8 in the supply line j should generally preferably be open, wherein the second primary circuit valve 8 generally serves to regulate the mass flow of the first heat transfer fluid to the first heat exchanger 9.
- the first fill level controller throttles the valve 8 and opens the valve 6, so that at least part of the product flow d reaches the process heat exchanger 7 without flowing through the first heat exchanger 9. This may become necessary if the amount of heat coming from the reactor is greater than that for which the heat recovery system is designed.
- the process heat exchanger 7 can temper the first heat transfer fluid coming from the supply lines f and k. The tempered first heat transfer fluid is then added to the mixer 1 through line i. The cooling or heating medium for the process heat exchanger 7 is supplied to the process heat exchanger 7 through the supply line g and is discharged from the process heat exchanger 7 through line h.
- the process heat exchanger 7 When the heat recovery system is in operation, the process heat exchanger 7 is generally in standby mode and is therefore not operated. Cooling takes place in the first heat exchanger 9, and only if the heat cannot be recovered by the heat recovery system does the process heat exchanger 7 preferentially assume part of the cooling of the product stream d.
- the further controller QC which is preferably a PID controller, preferably reduces the heat flow from the reactor 2 to the stratified storage tank 20 by opening the valve 8 in the inlet to the first heat exchanger 9 less and opening the valve 6 in the inlet to the process heat exchanger 7 more, as shown in Fig. 5.
- the additional heat exchanger of the closed heat pump circuit evaporates the water supplied to it on its secondary side into steam. This can, for example, generate steam with an absolute pressure in the range of 1.5 to 2.0 bar. Any downstream compressors can then increase the steam pressure and temperature. Examples
- ModelFit-Cybernetica for example 1. Details can be found on the website: "Model Predictive Control - Cybernetics" (accessed on September 7, 2023).
- the simulation depicts a heat recovery system according to the invention shown in Fig. 1 and simulates the method for operating the heat recovery system shown in Fig. 1.
- the model of compressor 18 and reactor 2 is not included in the simulation. This is achieved by having compressor 18 operate automatically within its load range between 60 and 100% depending on the mass flow and the temperature of the demineralized water p, and by having reactor 2 deliver a predetermined heat flow through line d.
- the simulation tests the control concept of the heat recovery system, including the control loops. This reveals any excessive temperature or other inadmissible operating points.
- the simulation checks the behavior of the fill levels in the first heat storage unit 10 and the second heat storage unit 14, the temperatures upstream of the first heat storage unit 10 and upstream of the second heat storage unit 14, and the heat flow rates used for steam generation in the heat exchanger unit 13.
- the simulation determines the effects of a change in the tank volume of one of the two heat storage units 10, 14 on the frequency of switching the compressor 18 on and off. 4. The simulation determines the effects of a change in the tank volume of one of the two heat storage units 10, 14 on the amount of recovered heat.
- the first heat storage unit 10 and the second heat storage unit 14 each have a tank volume of 2500 m 3 .
- the fill level setpoint of the first heat storage unit 10 for the load controller UC is 31% based on the maximum fill level.
- the maximum heat flow for steam generation is 4359 kW, which would mean that the compressor would be operating at 100% load.
- the first heat transfer fluid in the line d would be at least partially conveyed to the heat exchanger 7 so that the filling level of the first heat storage unit 10 can decrease accordingly.
- the ratio between the maximum heat flow for steam generation and the minimum heat flow for steam generation is 1.67, since the compressor 18 in this example 1 is only intended to operate in its load range between 60 and 100%.
- the operating load of the compressor at 60% corresponds to the minimum heat flow for steam generation
- the operating load of the compressor at 100% corresponds to the maximum heat flow for steam generation.
- the maximum permissible fill level in the first heat storage unit 10 is 95% of the maximum fill level. Before this value is exceeded, the first heat transfer fluid is fed to the heat exchanger 7 via line d.
- Example 1 shows that the fill levels of the two heat storage units 10 and 14, as well as the heat flow for steam generation, remain within the permissible range.
- the temperature fluctuations of the second heat transfer fluid upstream of the first heat storage unit 10 are in the range of 85 to 105 °C.
- the heat flow for steam generation can assume all values between the minimum and the maximum heat flow for steam generation, as provided by the control system.
- the simulation shows that the heat flow from reactor 2 integrated over the 20 days corresponds to the amount of heat used to generate steam during those 20 days. This is possible because the simulation does not consider heat losses to the environment.
- the first heat transfer fluid in the line d would be at least partially conveyed to the heat exchanger 7 so that the filling level of the first heat storage unit 10 can decrease accordingly.
- the minimum heat flow for steam generation is 2428 kW, at which the heat recovery system is in operation.
- the ratio between the maximum heat flow for steam generation and the minimum heat flow for steam generation is 1.67, since compressor 18 is also only intended to operate within its load range between 60 and 100%.
- the compressor's operating load at 60% corresponds to the minimum heat flow for steam generation
- the compressor's operating load at 100% corresponds to the maximum heat flow for steam generation.
- the threshold value of the filling level in the first heat storage unit 10 is 10%, based on the maximum filling level, at which the mode of no heat recovery is switched to the mode of minimum heat recovery.
- the threshold value of the filling level in the first heat storage unit 10 is 33%, based on the maximum filling level, at which switching from the minimum heat recovery mode to the maximum heat recovery mode takes place.
- the threshold value of the filling level in the first heat storage unit 10 is 23%, based on the maximum filling level at which switching from the maximum heat recovery mode to the minimum heat recovery mode takes place.
- Figure 4 presents the results of the simulation, with the heat recovery system shown in Fig. 1 operating for 20 days.
- the top plot shows the filling level of the first heat storage unit 10 by the solid line and of the second heat storage unit 14 by the dashed line over time, where 1 corresponds to the maximum filling level in each case.
- the plot in the middle shows two heat flows, each in the unit kW, over time.
- the solid line corresponds to the heat flow for steam generation, while the dashed line corresponds to the heat flow of the first heat transfer fluid from reactor 2 in line d.
- the lower plot represents the temperature in degrees Celsius over time.
- the solid line corresponds to the temperature of the second heat transfer fluid in the first heat storage unit 10, while the dashed line corresponds to the temperature immediately before the first heat storage unit 10.
- the simulation shows that the fill levels of the two heat storage units 10 and 14, as well as the heat flow for steam generation, remain within the permissible range.
- the temperature fluctuations of the second heat transfer fluid upstream of the first heat storage unit 10 are in the range of 85 to 105 °C.
- the heat flow for steam generation can only assume the predetermined minimum or the predetermined maximum heat flow, as provided by the control system.
- the simulation shows that the heat flow from reactor 2 integrated over the 20 days corresponds to the heat quantity required to generate steam during the 20 days. This is possible because the simulation does not take heat loss to the environment into account.
- Comparative Example 1 represents the steam generation according to Fig. 1, wherein the heat storage units 10 and 14 are not present. As a result, no energy from the batch reactor 2 can be stored in this Comparative Example 1. Consequently, no more steam can be generated once the reactor is not in operation and has cooled down.
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Abstract
L'invention concerne un système de récupération de chaleur perdue pour la production de vapeur d'eau pour des installations industrielles chimiques comprenant une installation industrielle chimique pouvant fonctionner de manière discontinue avec au moins un réacteur (2) pouvant être refroidi et raccordé à un circuit primaire, le ou les réacteurs (2) étant conçus de sorte, que, pendant le fonctionnement du réacteur (2), une réaction d'un mélange réactionnel a lieu et que la chaleur perdue produite par le refroidissement du réacteur (2) s'écoule à travers le circuit primaire soit sous la forme d'un liquide chauffé, soit sous la forme du mélange réactionnel lui-même en tant que premier fluide caloporteur, le circuit primaire reliant fluidiquement le réacteur (2) à un premier échangeur de chaleur (9) de sorte que le premier fluide caloporteur soit refroidi dans le premier échangeur de chaleur (9) et est ensuite renvoyé au réacteur (2) pour refroidir le réacteur (2), et un circuit secondaire contenant un deuxième fluide caloporteur séparé, qui est accouplé au premier échangeur de chaleur (9) de sorte que, pendant le fonctionnement du ou des réacteurs (2), le deuxième fluide caloporteur soit chauffé par le premier fluide caloporteur, et le circuit secondaire relie fluidiquement entre eux, à partir du premier échangeur de chaleur (9), une première unité d'accumulation de chaleur (10) montée en aval, une unité d'évaporation (13) montée en aval de la première unité d'accumulation de chaleur (10), une deuxième unité d'accumulation de chaleur (14) montée en aval de l'unité d'évaporation (13) et le premier échangeur de chaleur (9) monté en aval de la deuxième unité d'accumulation de chaleur (14), fermant ainsi le circuit secondaire, l'unité d'évaporation (13) étant conçue de sorte qu'une vapeur d'eau soit générée pendant le fonctionnement du système de récupération de chaleur perdue et est de préférence fournie à au moins un compresseur (18).
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP23202729.2 | 2023-10-10 | ||
| EP23202729 | 2023-10-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2025078187A1 true WO2025078187A1 (fr) | 2025-04-17 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/EP2024/077414 Pending WO2025078187A1 (fr) | 2023-10-10 | 2024-09-30 | Système de récupération de chaleur perdue pour la production de vapeur industrielle |
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| WO (1) | WO2025078187A1 (fr) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20100319348A1 (en) | 2009-05-26 | 2010-12-23 | Worleyparsons Group, Inc. | Waste heat recovery system |
| KR20150032241A (ko) | 2013-09-17 | 2015-03-25 | 주식회사 엘지화학 | 열 회수 장치 |
| WO2015041474A1 (fr) * | 2013-09-17 | 2015-03-26 | 주식회사 엘지화학 | Dispositif de récupération de chaleur |
| US20230287808A1 (en) * | 2020-11-23 | 2023-09-14 | Pintail Power Llc | Start-up and control of liquid salt energy storage combined cycle systems |
-
2024
- 2024-09-30 WO PCT/EP2024/077414 patent/WO2025078187A1/fr active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20100319348A1 (en) | 2009-05-26 | 2010-12-23 | Worleyparsons Group, Inc. | Waste heat recovery system |
| KR20150032241A (ko) | 2013-09-17 | 2015-03-25 | 주식회사 엘지화학 | 열 회수 장치 |
| WO2015041474A1 (fr) * | 2013-09-17 | 2015-03-26 | 주식회사 엘지화학 | Dispositif de récupération de chaleur |
| US20230287808A1 (en) * | 2020-11-23 | 2023-09-14 | Pintail Power Llc | Start-up and control of liquid salt energy storage combined cycle systems |
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