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Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 1
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
MULTI UTILITY HEAT PUMPS
Some Technologies Developed
at
the Heat Pump Laboratory at IIT Bombay, HPL_IITB
Indian Patents Filed 27 (14 Granted + 1 defended/awaiting grant + 12 being examined)
Several Technologies Developed / Transferred / Licensed / Commercialized
Milind V Rane, PhD
Institute Chair Professor and Energy Technology Consultant
Heat Pump Laboratory, HPL_IITB
Department of Mechanical Engineering
Indian Institute of Technology Bombay, Mumbai 400 076 INDIA
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 2
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
OUTLINE OF PRESENTATION
Multi Utility Heat Pumps
• Brief Overview of Various Technologies
Electric and Heat Driven Multi-Utility Heat Pumps, Heat Recovery, Renewables
• Need and Scope for Multi Utility Heat Pumps
• Various Multi Utility Heat Pump and their Salient Features
Salient Features of the Novel Patented Tube-Tube Heat Exchanger, TT_HE
Multi stream heat exchanger simplify controls
• Applications of Multi Utility Heat Pumps
• Case Studies along with Economics
60 TR R717 refrigeration system at a Dairy
33 kWh MU_HP Solution Heater at Automotive Factory
1.2 TR Ground Water Coupled AC at an Institute
36 kWh Air Source Heat Pump Water Heater for Buildings
4-in-1 Heat Pump for Residence
6-in-1 Heat Pump for Canteen
• Conclusions
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 3
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
Presented by Prof M V Rane on 23/11/2011 at the Energy Management CEP at DESE IITB Heat Pump Laboratory, IITB 3
Saved as G:\CEP\EC+DESE+2011\ECuHP+2011.ppt file last updated on 18/11/2011 at 15:00 hrs
MULTI_UTILITY HEAT PUMPS & SHR_WHSMU_HP deployed as 3.52 kW Residential to 55 kW Industrial Heating
SHR_WH deployed on 1 TR to 270 TR Air Conditioning and Refrigeration Systems
Applications: Heating Air / Water / Process Fluid, Cooling Air / Water / Potable Water / Process Streams
Vented Double Wall Tube-Tube Heat Exchanger, TT_HE Reliability Proven: SHR_WH operating over 8 years without service call
Installations at McDonalds, Mahindra & Mahindra , Worli Dairy, Hotel Faryaz, Club Mahindra, ENT Clinic, Homes, Hostel, etc
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 4
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
Presented by Prof M V Rane on 23/11/2011 at the Energy Management CEP at DESE IITB Heat Pump Laboratory, IITB 4
Saved as G:\CEP\EC+DESE+2011\ECuHP+2011.ppt file last updated on 18/11/2011 at 15:00 hrs
SORPTION REFRIGERATION SYSTEMS
Hybrid Air Conditioners Energy Efficient AC using Liquid Desiccant
Shipboard Chilling System Engine Exhaust used to Chill Water
Liquid Desiccant based Solar Multi-Utility Heat Pump AC + Potable Water + Hot Water
Diabatic Contacting Devices Enable Effective Heat and Mast Transfer with High Surface Density at Low Gas Phase Pressure Drop
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 5
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
Presented by Prof M V Rane on 23/11/2011 at the Energy Management CEP at DESE IITB Heat Pump Laboratory, IITB 5
Saved as G:\CEP\EC+DESE+2011\ECuHP+2011.ppt file last updated on 18/11/2011 at 15:00 hrs
RENEWABLE ENERGY SYSTEMSPlastic Wind Mill 0.125 kW @ 6 m/s Plastic Solar Air Heaters Air In/Out 29 / 60 to 90oC
Solar Steam Generator 1 bar @ 100oC Solar Refrigerator Cum Water Heater
Solar Air Heaters Air In/Out 29 / 150 to 300oC
Light Weight - Low Cost - Roof Mountable Systems of All Sectors Residential, Commercial and Industrial Use
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 6
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
RENEWABLE ENERGY SYSTEMS
Solar Flat Plate Air Heaters Ambient Air Heating form 25 to 75oC
Solar Flat Plate Steam Generators Tap Water to Steam at 100oC
Seasonally Tracked Collector
Once in 15 days
Light Weight
7.5 to 12 kg/m2
Efficiency Air Heaters
50 to 80% based on Global Radiation
Efficiency Steam Generators
40 to 60% based on Global Radiation
Low Cost
INR 4,100 to 6,000/m2for air heaters
INR 6,000 to 7,500/m2for steam generator
Applications
Cooking & Process Heating in
Residences, Commercial
and Industrial Establishments
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 7
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
RENEWABLE ENERGY SYSTEMS
Solar Steam Generator with Storage Currently Generates Steam @ 1 bar @ 100oC
Solar Rice Cooker Coupled with Solar Steam Generator with Storage
Seasonally Tracked
Once in 15 day if desired
Storage Temperature
Up to 200oC achieved
Efficiency
40 to 60% based on Global
Radiation
Low Cost
INR 7,500 to 10,000/m2
for steam generator with
storage
Applications
Cooking & Process
Heating in
Residences, Commercial
Industrial Establishments
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 8
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
Presented by Prof M V Rane on 23/11/2011 at the Energy Management CEP at DESE IITB Heat Pump Laboratory, IITB 8
Saved as G:\CEP\EC+DESE+2011\ECuHP+2011.ppt file last updated on 18/11/2011 at 15:00 hrs
EXHAUST HEAT RECOVERY UNITS
Deployed on 50 kW to 7.5 MW Gas Turbines, 135 kW to 6 MW DG Sets
Applications: Heating Air / Water / Thermic Fluid, Generating Steam / NH3/H2O Solution / Liquid Desiccants
Heat Sources: Exhaust of Engines & Gensets Diesel / Gas / FO / Biogas, Turbines Gas / Biogas , Furnaces, Stenters
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 9
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
HEAT PUMPS AND WASTE HEAT RECOVERY
Need and Scope
• Improve Life Cycle Cost
Minimize need for cooling by judiciously selecting indoor/outdoor conditions, recovering and recycling availability in exhaust streams, proper application engineering
Lower operating cost due to higher overall energy efficiency
Peak demand for domestic water heating can be reduced by over 95%
Co-production of multiple utilities using a single system helps reduce space, initial cost and maintenance
• Scope for Developing & Deploying Appropriate Technologies
Reliable and compact heat and mass exchangers need to be developed to tap the potential savings
Good application engineering for judicious non-intrusive integration of various sub-systems
• Energy Conservation
Co or tri-generation of cold, hot and/or dehumidification utilities
Super heat recovery with chiller COP and/or capacity improvement
Preheating of boiler feed water, which is free if primary useful effect is cooling and vice versa
• Environmental Friendly
Co-production of multiple utilities helps improve cooling capacities/COP and reduce refrigerant charge, reduces material usage and embodied energy
Thermal pollution & CO2 emission reduced by gainfully recovering heat in multi-utility generator
Using renewables with suitable backups helps reduce fuel, heat pumps as backup for water heating
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 10
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
ISSUES RELAVENT TO DESIGN OF MUHPs
Systems Need to be Custom Designed and Optimized
• Design Should be Arrived at After Giving Due Consideration to
Variation in Load Pattern: design load
Specific Process Requirements: mode of heat recovery, in the form of potable hot water, boiler feed water, direct heating of process fluids or sea water for desalination, regeneration of liquid desiccant
Water Quality: passage dimensions
Concept and Culture of Maintenance: reflects on water passage dimension
Choice of Wetted Material: Tube MOC has to be appropriately selected and wall thickness is to be determined based on corrosion characteristics and expected life
Available Space: Coil design could be optimized by selecting most suitable configuration from options like serpentine, compressed serpentine, helical, flat helical, spiral, with optimal straight sections between bends, etc.
• Variables that Play an Important Role in Design Optimization
Pressure Drop on Refrigerant Side: affects size, weight and cost; specially capacity of the chiller/refrigeration unit may reduce if not designed properly
Refrigerant Velocities: oil return and heat transfer coefficients
Water Velocities: fouling, heat transfer coefficients and pumping costs
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 11
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
TUBE-TUBE HEAT EXCHANGERS
Reliable Vented Double Wall Heat Exchanger
Based on Contributions of the HPL_IITB
Indian Patents Filed 1 (Tube-Tube Heat Exchanger)
Patent granted (Application number: 1082/MUM/2002, Grant number: 205362)
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 12
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
HEAT RECOVERY WATER HEATER
Generate Cold and Hot Utilities Simultaneously using SHR_WH or MUHP
Features of Patented Tube_Tube Heat Exchangers, TT_HE
• Novel Modular Design: Vented tube-tube design, starting with 0.5 TR module with increments of 1 and 5 TR, no upper limit for chiller capacity
• Safe Integration in to the System: Vented design ensures no mixing of refrigerant and water, SHR_WH can be isolated while chiller is on line
• Simple to Retrofit: Only the tube/pipe between compressor and condenser is tapped into to install the SHR_WH
• High Heat Transfer Coefficients: Novel tubular exchangers optimized for high heat transfer coefficients at low pressure drops on water/refrigerant sides
• Material of Construction: Wide choice of MOC, optimized based on the application, SS 316L, SS 316, SS 304L, Mild Steel, Carbon Steel, Copper
• Easy to Maintain: Can be cleaned in place using Chemical Descaling Fluids while keeping the chiller/refrigeration system online
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 13
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
SHR_WH NDRI 60 TR R717 WCCOperational since Jan 2016 by Promethean Energy Pvt Ltd, Navi Mumbai
Water Heating 800 lph from 30 C to 60oC, 30 kWh Pressure Drop <0.1 bar
Condenser Pressure Reduced
• Refrigeration System Capacity Kirloskar Reciprocating Ammonia Compressor in a Dairy 60 TR (210 kWc )
• Temperature of Refrigerant, In/Out 100/50oC
• Temperature of Water, In/Out 30/60oC
• Hot Water Flow Rate 800 l/h
• Simple Payback ~6 month
• Easy to Integrate / Retrofit in Existing Operating Plant
Installation Possible with Shutdown of Half A Day!
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 14
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SHR_WH INDIAN RAYON 110 TR R134a WCCOperational since Oct 2015 by Promethean Energy Pvt Ltd, Navi Mumbai
Free Water Heating 77,000 lpd, from 29 C to 41oC, 46 kWh Chiller Power Saving ~1% Capacity Maintained
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 15
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CASE STUDYOperated for Eleven Years without a Single Service Call
Super Heat Recovery Water Heater at Hotel Fariyas, Colaba
• Chiller Capacity 60 TR (211.2 kWc )
R22 York Reciprocating Compressor
• Temperature of Refrigerant, In/Out 95/63oC
• Temperature of Water, In/Out 30/60oC
SHRWH is installed in co-current mode
• Hot Water Flow Rate 870 l/h
• Fuel Saving Reported 81 l HSD/day
• Annual Savings INR 10 Lakh/y
• CO2 Emissions Reduction 1100 tonne in 11 year
• Simple Payback < 3 month
Without accounting for electricity saving due to improved COP
Without accounting for 80% depreciationb
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 16
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
VARIOUS TYPES OF HEAT PUMPS
• Vapour Compression: Electric Motor or Direct Engine Coupled
Heating only
Heating in winter and cooling and dehumidification in summer/monsoon
Simultaneous cooling and heating
Multi-utility generator for simultaneously catering to air-conditioning, water heating and potable water
chilling
• Absorption and Adsorption: Waste Heat or Solar Driven or Biogas/Biomass Fired
Co or tri-generation of cold, hot and/or dehumidification utilities
Solar refrigerator cum water heater
Solar dehumidified fresh air, potable water generation, water heating
Solar cold store cum dryer
Biogas fired cold store cum dryer
Solar cold store cum dryer with biogas backup
Shipboard fish chilling system using engine exhaust heat
Tractor cabin air conditioner using hot water from engine
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 17
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
EFFICIENT HEATING FOR AUTOMOTIVE INDUSTRY
M&M KANDIVILI
Heat Duty 33 kW, Power Input 11 kW, Heater Power Saving 60 to 70%, Solution Heated up to 55oC
Bonus Utilities Generated: Cooling of Shop Floor and Potable Chilled Water 300 lph at 18oC
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 18
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
HEAT PUMP
for Washing Machine Coolant Heating on Washing M/C # 1729
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 19
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
AIR & WATER TO WATER MULTI-UTILITY HEAT PUMP
Energy Efficient Process Fluid Heating and Simultaneous AC and Water Cooling
for Automotive Industries, Small Scale Industries and Agro Processing Units
Heating Duty 36 kWh
Water Heating from 50 to 55oC
Power Input 12 kWe
Heater Power
Saving 60 to 70%
Bonus Utility
Generated
Chilled Water 4.2 kWc
Water Chilled from 12 to 7oC
Air Cooling 19.8 to 24 kWc
Indoor Temperature 27 to 18oC
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 20
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
CASE STUDY
Heat Pump Installation on Washing M/C # 1729 at M&M Kandivli
Utilities Produced ESH HP
Synclean Solution Heating to 55oC 66 kW 33 kW
Potable Water Cooling 4.1 kW
Air Conditioning 6.5 TR
Power Consumed ESH HP
Electric Solution Heater (ESH) @ (2+8) h/day 66 kW2 h preheating @ 100% duty and 8 h @ 50% duty cycle
Heat Pump + Solution Pump @ (4+8) h/day (10 + 1) kW 4 h preheating @ 100% duty and 8 h @ 100% duty cycle
Total Power Consumption 396 kWh/day 132 kWh/day
Reduction in Power Consumption 66%
Total Operating Cost @ 4 INR/kWh 1584 INR/day 528 INR/day
Saving in Operating Cost 1045 INR/day
Total Capital Cost of Heat Pump Installation INR 4.10 Lac
Annual Savings in Operating Cost INR 3.13 Lac
Simple Payback for Other Installation < 1.5 yearOne shift operation without accounting for the initial investment required for the equipment
needed for generating cold utilities and the cost of operating the cold utility generators
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 21
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3rd BRY-AIR AWARDS FOR EXCELLANCE IN HVAC&R 2007-08
Multi-Utility Heat Pumps Won the Runner-Up Trophy in the Product Category
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 22
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
WATER TO WATER MULTI-UTILITY HEAT PUMP
Energy Efficient Water Heating and Simultaneous Water Chilling for Hotels
Heating Duty 55 kWh
Water Heating from 27 to 60oC
Power Input 15 kWe
Heater Power
Saving 60 to 70%
Bonus Utility
Generated
Chilled Water 43 kWc
Water Chilled from 12 to 7oC
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 23
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
MULTI-UTILITY HEAT PUMPS: MU_HP
Generating Multiple Cold and Hot Utilities Simultaneously since June 2003
Novel 4 in 1 Heat Pumps
• Novel Design: 4 in 1 unit with provision for air conditioning using radiant panels, water
heating, potable water cooling and cloth drying
• Integrated System: Includes tap water heater and potable water cooler
• 24 hour Supply of Hot and Cold Water: Storage required
• Simple to Operate: Simply turn on the hot or chilled water tap to draw water
• Chills Potable Water to 18oC: 0.5 L/min or 30 L/h
• Heats Tap Water to 45oC: 3 to 4.5 L/min or 180 to 270 L/h in a 1.5 TR AC
• Low Operating Costs: 60 to 70% reduction in operating costs
• Lower Initial Cost: Compared to the conventional air conditioner + electric water heater + water
cooler
• Compact Design: Same footprint as that of Window or Split Air Conditioner
• Maintenance Free: Operating for over 12 year at Prof Rane’s Residence in IITB
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 24
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MULTI-UTILITY HEAT PUMPS: MU_HPOngoing Project at NTPC_NETRA: IITB_NTPC Joint Project
Generation of Multiple Cold and Hot Utilities Simultaneously
Novel 6 in 1 Heat Pump for Canteen Application
• Integrated System: All season heat pump includes water heating/cooling and refrigerator
• Air Conditioning: 12 TR cooling/dehumidification in summer/monsoon and heating in winter
• Simple to Operate: Simply turn on the hot or chilled water tap to draw water
• Supply of Cold and Hot Water on Demand: Integrated storage with Patented TT_HE
Cooled RO water @ 15oC for drinking 200 L storage Max Demand Served 16 kW
Heated tap water @ 60oC for sanitation 1,500 L storage Max Demand Served 35 kW
Heated RO water @ 80oC for cooking 200 L storage Max Demand Served 50 kW
• Refrigerator for Preserving Fresh Fruits & Vegetables along with Milk Products
Refrigerator @ 10 to 15oC for food 1,000 L storage 24 h Operation
• Low Operating Costs: 2.65 Lac INR/year compared to non-solar option
• Compact Design: Footprint ~3 m L x 1.22 m W x 2.1 m H located outdoor including storage
• Payback: Less than 1 year for non-solar option based on 7 h/day & 300 day/year operation
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 25
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PANEL HEAT EXCHANGERS
Handles Both Sensible and Latent Loads & Offers Built in Storage
Based on Contributions of the HPL_IITB
Indian Patents Filed 1 Panel Heat Exchanger
Patent Application #: 1828/MUM/2014
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 26
Saved as F:\CEP\TG+ESE_IITB+2015-2016\20160303+HP&WHR+TG_ESE+M V Rane+20160309.pptx file last updated on 23-03-2016 2.06 PM
MU_HP: DX Radiant Panel in the HallMU_HP operating for over 11 year, since Jun 2003, at Prof Rane’s Residence in IITB Radiant Panels Integrated in Aug 2014
Handle Both Sensible and Latent Loads: ~1.8 m2/TR Wall Area
• High Performance: DX coil can operate at 12oC in place of 7.2oC
Results in increased cooling capacity and COP of the refrigeration system
• Attractive Initial Cost: Comparable with cassette type indoor units
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 27
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ENERGY EFFICIENT INSTANT WATER COOLER Radiant Heat Rejection Panel from the Condenser
Features of EE_IWC
• Chilled Drinking Water 50 lph
Delivered at 18oC
Instant cooling effect
• Filtered Warm Water is Coproduced
• Energy Efficient System
Lower power consumption 480 to 500 W
Novel Design, Radiant Cooled Condenser
• Ease of Servicing
Fin tube condenser coil and fan is absent
• Option to Conceal Aqua Guard Water Filter
• Footprint of the System is Very Small
Less than 0.2 m2
915 mm
1390 mm
2438 mm
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 28
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MULTI-UTILITY HEAT PUMP WITH CONTACTING DEVICE
Energy Efficient Air Conditioning using Novel Evaporative Condensation at McDonalds
Conventional AC Duty 24 TR, Power Input 1.01 kWe/TR, Power Saving 25 to 36%, Water Heated up to 55oC
Bonus Utilities Generated: AC of Kitchen, Water Heated 500 lph at 55oC and Potable Chilled Water 300 lph at 18oC
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 29
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SOLAR MULTI-UTILITY HEAT PUMP: SMUHP3 TR Fresh Air Dehumidifier + 50 to 80 lpd Potabel Water Generation + Potabel Water Heating upto 800 lpd
Air Conditioning Unit Including Evaporative Cooler & Solar Collector
• Indirect Evaporatively Cooled Fresh Air Dehumidifier
Three stage counter current Heat and Mass Transfer
Built In Indirect Evaporative Cooling
Diabatic Contacting Devices, DCD, used a FAD, EC, LT LDR
• Two Stage Regeneration using EGT based Solar Collectors
Regeneration max 135oC using EGT Heat Pipe Collectors
• Initial Trials have Demonstrated Dehumidification COP > 1.0
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 30
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SOLAR AIR CONDITIONING3 TR Solar Air Conditioner with Co-generation of Hot Water and Potable Water
System Integrated Preliminary Tests Show Dehumidification COP 1.03
• Liquid Desiccant based Solar Multi-Utility Heat Pump, LD_SMUHP
Air Conditioning room air at DBT 26+2oC & rh 60% 3 TR (10.5 kWc)
Tap Water Heating from 27 to 50oC 500 to 800 lpd
Potable Water Generation 50 to 80 lpd
• Solar Collectors Serve As High Temperature Regenerator, HTR
Serviceable Heat Pipe Integrated EGT SC used as HTR Modules to regenerate ~8.1 kg/h
Four roof mountable HTR modules deployment on HPL_IITB Terrace 13.5 m2
Collectors with Projected EGT Absorber 3 to 3.6 m2 & Gross Area 6 to 7.2 m2 (27 m2 Gross Area)
Collector efficiency @ 750 W/m2 global and regeneration temperature of 135oC > 50%
• Diabatic Contacting Device, DCD Serve as Low Temperature Regenerator, LTR
Slow Rotating Disk Assembly in DCD used to regenerate additional ~6.5 kg/h
Two Troughs /DCD used for 3 TR LD_SMUHP 2 x 1.5 m L
Mass transfer surface area 16.6 m2
Rotor motor power consumption < 10 W
• KFo Solution Concentration Change Achieved in HTR & LTR up to 18%
• High and Low Temperature Solution Heat Exchangers are Three Fluid Stream HEs
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 31
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CONCLUSIONS
Energy Conservation In HVAC&R: SHR_WH, MUHP
• Increasing Energy Costs and Raising Concern for Environment Heightens the Need to Go for
Heat Recovery Systems: SHR_WH and Multi-Utility Heat Pumps
• Novel Patented Tube-Tube Heat Exchangers (TT_HE) are Very Reliable
Double Wall Vented Design no worries about cross contamination
More Reliable than the conventional condensers and chillers
• Recovered Heat from Chillers / Refrigeration Systems can be Effectively Used for
Generating hot water, process fluids or desalinating sea water
Regenerating liquid desiccant for drying and dehumidification
• Super Heat Recovery Water Heaters, SHR_WH, are Very Lucrative
Water can be heated to over 75oC while simultaneously increasing cooling COP and capacity of the
vapour compression refrigeration / chiller system
• Payback for Novel Patented SHR_WHs Range Between 3 to 6 month
• Multi-Utility Heat Pumps can Reduce Electric Demand by 66 to 95%
• Payback Periods for Multi-Utility Heat Pumps Range Between 3 to 18 month
Open Up New Applications with Economically Attractive Possibilities for Deployment !
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 32
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THANK YOU ALL!
Principal Investigator
Dr Milind V Rane
Institute Chair Professor and Energy Technology Consultant
Heat Pump Laboratory at IIT Bombay, HPL_IITB
Mechanical Engineering Department
Indian Institute of Technology Bombay, Mumbai 400 076 INDIA
Phone Off 2576 7514, Lab 2576 4593, Res 2576 8514
Fax Off (9122) 2572 3480, Res (91 22) 2572 4544
Email ranemv@iitb.ac.in
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 33
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Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 34
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VARIOUS HRU DESIGN ISSUES
Systems Need to be Custom Designed and Optimised
• Design Should be Arrived at After Giving Due Consideration to
Variation in load pattern
Design load
Specific process requirements
Mode of heat recovery, in the form of steam, thermic fluid, hot water, regeneration of salt solutions or hot air
Water quality
Passage dimension
Concept and culture of maintenance
Gas side passage dimension
• Variables that Play an Important Role in Design Optimisation
Pressure drop on exhaust side affects
Size, weight, cost
Exhaust gas velocities
Fouling, heat transfer coefficients
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 35
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Heat Pump Laboratory, IITB 35 of 54
MATRIX HEAT RECOVERY UNITCompact Boilers Along Side the Silencers for 2 x 1000 kVA DG Sets
Applications: Heating Air / Water / Thermic Fluid, Generating Steam / NH3/H2O Solution / Liquid Desiccants
Heat Sources: Engines & Gensets Exhaust Diesel / Gas / FO / Biogas, Turbines Exhaust Gas / Biogas
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 36
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Heat Pump Laboratory, IITB 36 of 54
GAS TURBINE EXHAUST HEAT RECOVERYApplication: Heating Thermic Fluid
Compact Thermic Fluid Heater for 7.5 MW Turbomac Gas Turbine
Exhaust Flow Rate 26.23 kg/s
Temperatures In / Out
Exhaust 484 / 424oC
Thermic Fluid 220 / 250oC
Heat Duty 1.72 MW
Pressure Drop
Exhaust < 60 mm H2O
Thermic Fluid < 1 bar
Size (excluding duct work)
Length 1000 mm
Width 2750 mm
Height 1400 mm
Weight 1400 kg
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 37
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VASVIK AWARDS FOR INDUSTRIAL RESEARCH 2005
Matrix Heat Recovery Units and Heat Recovery form RAC Systems
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 38
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DIABATIC CONTACTING DEVICE
Compact Diabatic or Adiabatic Mass Transfer Device
Based on Contributions of the HPL_IITB
Indian Patents Filed 1 (Contacting Device)
Patent granted (Application number: 1082/MUM/2002, Grant number: 205362)
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 39
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DIABATIC CONTACTING DEVICE
Features and Advantages
• Modular, Scalable, Efficient and Economical
• Compact and Sturdy
High surface densities typically in the range of 465 to 600 m2/m3
120 to 185% greater than conventional packing
• Low Pressure Drop
Typically 10 to 60 Pa per stage
• Low Power Consumption for Rotor and Fan/Blower
Probably the lowest energy consuming aeration device with very high interfacial area
• Carryover Free
Stream of gas or air that flows out does not contain any liquid
Air velocities between 1 to 2.4 m/s : Depending on operating conditions
• Cost Effective with Early Payback
Use of Waste Heat and Low Pumping Power
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 40
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DIABATIC CONTACTING DEVICE
Applications Include Combined Heat and Mass Transfer
• Efficiently Absorb or Separate Gases from Liquids
• Distillation, Rectification, Solvent Recovery
Integration with Heat Pumps or Low Grade Heat Sources like Process Streams
• Absorption Refrigeration Systems
• Air Conditioning and Refrigeration Applications
Air Washers, Humidifiers and Dehumidifiers
• Liquid Desiccant Systems
Humidifiers and Dehumidifiers
• Hybrid Air Conditioning
using Liquid Desiccants and Vapour Compressor Systems
• Various Other Applications in Chemical Process Industries
Effluent Aeration, Concentration, Evaporation, Solvent Recovery
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 41
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TASK 3.2 A: DOAS & MCHXPrototype for Fresh Air Dehumidification or Evaporative Cooling using
Diabatic Contacting Device
• Prototype of a Versatile Patented Diabatic
Contacting Device with Rotating Contacting Disks
• Various Uses in Diabatic Contacting Device
Air Humidifier for use as a dessert cooler
Indirect Evaporative Cooler for cooling water
which could be used for structure cooling
Evaporative Condenser/De-superheater/Sub-
cooler for improving performance of air or water
cooled systems
Fresh Air Dehumidifier using Liquid Desiccant
while concurrently cooling using cooling tower
water and regenerating with hot water
Hybrid Air Conditioning System using Liquid
Desiccant for dehumidification with concurrent
cooling using evaporator of a vapour
compression sub-system and regenerating with
condenser heat
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 42
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COMPARISON OF DEHUMIDIFICATION PROCESSES
State Points on Psychrometric Chart
1-2-3-4 Conventional Vapour
Compression System
1-4 Hybrid Cooling System
A Heat Pump delivering Cooling
during Dehumidification along
with Regeneration of Liquid Desiccant
using Condenser Heat
1-5-4 Adiabatic Dehumidification
followed by Sensible Cooling
1-5-6-7-4 Adiabatic Deep
Dehumidification followed by
Sensible Cooling and Direct
Evaporative Cooling
-10 0 10 20 30 40 50
Temperature,oC
0
10
20
30
Hum
idit
y R
atio
, g/k
g D
ry A
ir
100%
70%
40%30%
10% Relative Humidity
0.77
0.79
0.81
0.83
0.85
0.89
0.91
0.93 Specific V
olume, m
3/kg Dry A
ir0.95
10
30 4
2 1
90
3
76
5
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 43
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HYBRID COOLING SYSTEM
Schematic Representation of Refrigerant and LD Circuits
LD Pump
LD Pump
Compressor
Regenerator/OutDoor ContactingDevice
Absorber/InDoor ContactingDevice
Contacting Disc
SHE
Throttle Value
Fan
Trough
Square Shaft
Weak LD
Strong LD
Rfrigerant Vapour
Fan
Ambient AirIn Door Air Conditioned Air
Presented by Prof M V Rane on 23/11/2011 at the Energy Management CEP at DESE IITB Heat Pump Laboratory, IITB 43
Saved as G:\CEP\EC+DESE+2011\ECuHP+2011.ppt file last updated on 18/11/2011 at 15:00 hrs
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 44
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HYBRID AIR CONDITIONING SYSTEM: HEAT PUMP!
Cooling Using VCS and Dehumidification Using Liquid Desiccant
Novel Contacting Device in ICD and
OCD
Large surface density
465 to 600 m2/m3
No carryover of LD
Low pressure drop
5 to 10 mm H2O
Features and Advantages
Increase in Cooling Capacity
20 to 40% for a given compressor
Energy Saving
30 to 60% compared to conventional
practice
Modular Design
2 to 50 kW cooling capacity
Low Initial Cost
compared to conventional solid or
liquid desiccant based systems
OCD
ICD
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 45
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SCHEME FOR LD_SACTwo Stage Regeneration of LD, Simultaneous Sensible and Latent Cooling for Hot and Humid Climate of Mumbai, INDIA
Advantages: High COP, Low Parasitic Power, No Carryover or Corrosion
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 46
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SOLAR AIR CONDITIONING3 TR Solar Air Conditioner with Co-generation of Hot Water and Potable Water
System Integrated Preliminary Tests Show Dehumidification COP 1.03
• Diabatic Contacting Device, DCD, Serve as Fresh Air Dehumidifiers, FAD
Slow Rotating Disk Assembly in DCD used to absorb moisture from fresh air ~14.6 kg/h
Cooling of the FAD is achieved using Indirect Evaporative Coolers, IEC
Six Troughs /DCD used for 3 TR LD_SMUHP 6 x 1.5 m L
Mass transfer surface area ~50 m2
Rotor Motor Power Consumption < 30 W
Double Inlet Blower Power for Fresh Air Circulation ~ 150 W
• Diabatic Contacting Device, DCD, Serve as Indirect Evaporative Coolers, IEC
Slow Rotating Disk Assembly in DCD used to evaporatively cool water ~10.5 kW
Cooling of the FAD is achieved using water cooled in IEC
Six Troughs /DCD used for 3 TR LD_SMUHP 6 x 1.5 m L
Mass transfer surface area ~50 m2
Rotor motor power consumption < 30 W
Axial Fan Power for Ambient Air Circulation through IEC & LTR ~ 100 W
Peristaltic Solution Pump Used for Circulation of KFo Solution 100 W
Water Circulation Pump in IEC 90 W
• Solar Air Conditioning is One Step Closer to Techno-Economic Viability!Expected mass production cost of 3 TR LD_SMUHP is INR 4.1 Lac with payback of 2 to 3 yr
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 47
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PANEL HEAT EXCHANGER: Cooling/Dehumidification/HeatingInstalled at the Heat Pump Laboratory at IIT Bombay, HPL_IITB
Two Panels, 3.7 m x 0.5 m, in Two Rooms Coupled to a Single 2 TR Split ODU
• Location of Panel Heat Exchanger
Mounted on the beam Located such that cooled dehumidified air
naturally convects down on the users around
the table
• Heat Transfer from Panel Surface
Radiation Component Panel temperature is 7.2 to 15oC
Higher if compressor supports such operation
Natural Convection Depends upon room indoor air velocity (0.2 to
0.5 m/s) using ceiling fan
Or benefiting from dehumidified fresh air
ventilation air
• Role of Existing Ceiling Fan
Forced Convection Air velocity on PHE increased: 0.5 to 2.0 m/s
depending upon location and user comfort
• Location of Room Thermostat
Can not see the panel – radiation effect
Presentation on Heat Pumps and Waste Heat Recovery by Prof M V Rane on 9/03/2016 in the CEP for the Tata Group Heat Pump Laboratory, IITB 48
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SOME TECHNOLOGY LICENSEE
Matrix Heat Recovery
Unidyne, Mumbai for Engine , Gas Turbine and Furnace Exhaust Heat Recovery
for Generation of Hot Water, Pressurised Hot Water, Steam,
Heating Thermic Fluid and Generation of NH3/H2O Solution
Tube –Tube Heat Recovery
Promethean Energy, Navi Mumbai for SHR_WH, Compressed Air Heat Recovery
Aqua Engineers, Mumbai for SHR_WH
Mech World Eco, Nashik for SHR_WH, Evaporator, Condenser, Potable Water Instant Pre Chillers
Contacting Device
Opel HVAC, Mumbai for HACS in Pharma Sector
Mech World Eco, Nashik for Evaporative Condenser
Vector Technologies, Mumbai for Evaporative Condenser, HACS
Adsorption Module
Godrej Lawkim, Pune for Solar Refrigerator cum Water Heater
Plastic Heat Exchanger
Vector Technologies, Mumbai for Air to Air Heat Recovery and Indirect Evaporative Cooling
Recommended