Latent Heat Storage for Process Heat Applications

Jochen Buschle
DLR German Aerospace Center
Institute of Technical Thermodynamics Stuttgart
Co-Authors: Wolf-Dieter Steinmann, Rainer Tamme The Tenth International Conference on Thermal Energy Storage, Atlantic City, 31. May 2. June 2006
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Content
Presentation is presenting first results obtained in the national project PROSPER dealing with industrial process steam storage. Possible contribution of Germany to planed new Annex 19. Project partners are XELLA AG and SGL Technologies GmbH Duration 07/2004 06/2007 The project is funded by the Federal Ministry of Economy (BMWi) under the contract FKZ 032736017

Latent heat steam storage in process heat applications Comparsion macro-encapsulation and external arrangement Simulation results Concepts to increase the power density of the storage Conclusion

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Gas concrete manufacturing process

Hardening of gas concrete (steam atmosphere; max 13 bar) Batch process, 2 cycles per day 155 kg steam at 13 bar for 1 m gas concrete = 100 kWhth Xella Porenbeton GmbH (300.000 m/a corresponds to 30 GWhth/a)

weighing and mixing

pressure [bar]

12 8 4 0 0 1 2 3 4 5 6 7 8 9 10 time [h]

cutting bulking

hardening

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varying-pressure accumulator - Ruths storage

Discharging pipe Pressure vessel

Steam Water Charging pipe

Water feed pipe

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Process description - State of the art

varying-pressure accumulators 2 Ruths steam accumulators 70% of the required steam per cycle is produced in the boiler
Ruthshigh pressure; 5% Ruthslow pressure; 15%

overflow; 10%

live steam; 70%

boiler

autoclave

3-5 bar

5-8 bar

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Potential for introducing latent heat steam storage

Isothermal steam accumulators with Phase Change Material (PCM) 2 PCM enhanced steam accumulators (Tm = 152C and 171C) 40% of the required steam per cycle is produced in the boiler
Latentlow pressure; 25% Latent-high pressure; 25% live steam; 40%

overflow; 10%

Latent heat storage boiler autoclave 5 bar

Latent heat storage 8 bar

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Macro encapsulation

PCM

Gas

Stiff encapsulation required Definition of minimal gas volume inside capsules Compensation of volume variation PCM Avoidance of significant pressure variations Gas volume requires about 20% of the internal volume of the capsules

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External arrangement of PCM

PCM

Additional required: Headers for the tube register Unpressurised containment for the PCM Pump for circulation required

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Comparison macro encapsulation and external arrangement

PCM

steam

Boundary conditions temperature step: 10 Kelvin pipe diameter: 40 mm heat transfer coefficient to the steam: neglected thermal conductivity PCM: 0.5 W/mK density PCM: 2000 kg/m same amount of PCM

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Macro encapsulation vs. external arrangement

solidified PCM mass [%]
100

80

60

40

External arrangement Macro encapsulation

20

0 0 500 1000 1500 2000 2500 3000 3500

time [s]

External arrangement shows higher power level assuming the same amount of pipe material
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Macro encapsulation vs. external arrangement

wall thickness [mm]
1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 2 6 10 14 18 22 26 30

externally arranged PCM External arrangement

Macro encapsulation encapsulated PCM

pressure [bar]

Outside pressure load demands higher wall thickness than inside pressure load due to buckling
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Comparison steam accumulator concepts

pressure vessel: diameter: 1m; height: 3m; volume: 2.36 m; water level: 80%

varying-pressure accumulator PCM enhancement:

Macro-encapsulated PCM

externally arranged PCM

diameter tube: 4 cm; mass PCM: 1250 kg; thermal conductivity: 0,5 W/(m K)

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Simulation modell
ramp

50

50

Po...

true

-1000

Pump 1
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Results simulation
kW
100 80 60 40 20 0 1000 2000 3000 4000 5000

Power

kWh
56 42 28 14 0 1000 2000

time [s]

Provided heat
3000 4000 5000

time [s]
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Required thermal conductivity

time [sec.]
1200 1000 800 600 400 200 0 0 5 10 15 20 25 30

h = 100000 W/(mK) h = 10000 W/(mK) h = 1000 W/(mK)

k [W/mK]

thermal conductivity above 5 W / (m K) is advantageous

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Basic concepts to increase the power density of thermal energy storage tested at DLR
Increase of the effective thermal heat conductivity Increase of the heat transfer area

PCM - Composite

Integretion of fins

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PCM Composite

Solution: Compression of Salt and expanded graphite Advantages expanded graphite: Hight thermal conductivity Corrosion resistance material can be machined

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Integration of Fins
Solution: Foils made of expanded graphite Advantages graphite foils: Hight thermal conductivity (approx. 150 W/mK) Corrosion resistance Arrangement of foils vertical to the axis of the heat transfer pipes is optimal with respect to the anisotropic heat conductivity of expanded graphite

Graphite-foil Graphite-foil 10 mm

PCM

PCM

PCM

PCM
Steam pipe 0,5 mm

PCM

PCM

PCM

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Lab scale experiments at DLR

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Conclusion

Isothermal energy storage is important especially for steam processes External arrangement of PCM is advantageous Thermal conductivity of 5 W / (m K) is required

Future work: Lab scale experiment for validation of models System simulation of gas concret production process with latent heat steam accumulator

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Thank You for Your Attention

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Latent heat steam accumulator

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