Techno-Economic Analysis of Waste Heat Recovery in Automotive Manufacturing Plants

This study proposes an innovative system for recovering waste heat from exhaust air after a regenerative thermal oxidiser process, integrating a Carnot battery and photovoltaic (PV) modules. The Carnot battery incorporates an organic Rankine cycle (ORC) with a recuperator, thermal energy storage (TE...

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Main Authors: Putu Diah Prajna Paramita, Sindu Daniarta, Attila R. Imre, Piotr Kolasiński
Format: Article
Language:English
Published: MDPI AG 2025-01-01
Series:Applied Sciences
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Online Access:https://www.mdpi.com/2076-3417/15/2/569
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author Putu Diah Prajna Paramita
Sindu Daniarta
Attila R. Imre
Piotr Kolasiński
author_facet Putu Diah Prajna Paramita
Sindu Daniarta
Attila R. Imre
Piotr Kolasiński
author_sort Putu Diah Prajna Paramita
collection DOAJ
description This study proposes an innovative system for recovering waste heat from exhaust air after a regenerative thermal oxidiser process, integrating a Carnot battery and photovoltaic (PV) modules. The Carnot battery incorporates an organic Rankine cycle (ORC) with a recuperator, thermal energy storage (TES), and heat pump. Waste heat is initially captured in TES, with additional energy extracted by a heat pump to increase the temperature of a secondary fluid, effectively charging TES from both direct and indirect sources. The stored heat enables electricity generation via ORC. The result of this study shows a heat pump COP between 2.55 and 2.87, the efficiency of ORC ranging from 0.125 to 0.155, and the power-to-power of the Carnot battery between 0.36 and 0.40. Moreover, PV generates 1.35 GWh annually, primarily powering the heat pump and ORC system pump. The proposed system shows a total annual net generation of 4.30 GWh. Economic evaluation across four configurations demonstrates favourable outcomes, with a return on investment between 25% and 160%. The economic evaluation examined configurations with and without the PV system and recuperation process in the ORC. Results indicate that incorporating the PV system and recuperator significantly increases power output, offering a highly viable and sustainable energy solution.
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institution Kabale University
issn 2076-3417
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publishDate 2025-01-01
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series Applied Sciences
spelling doaj-art-7cb97a6c33154aa6b5df1d29e564ba7a2025-01-24T13:19:52ZengMDPI AGApplied Sciences2076-34172025-01-0115256910.3390/app15020569Techno-Economic Analysis of Waste Heat Recovery in Automotive Manufacturing PlantsPutu Diah Prajna Paramita0Sindu Daniarta1Attila R. Imre2Piotr Kolasiński3Department of New Model PL, PT Honda Prospect Motor, Jl. Mitra Utara II, Karawang 41363, IndonesiaDepartment of Energy Engineering, Budapest University of Technology and Economics, Műegyetem rkp. 3, H-1111 Budapest, HungaryDepartment of Energy Engineering, Budapest University of Technology and Economics, Műegyetem rkp. 3, H-1111 Budapest, HungaryDepartment of Thermodynamics and Renewable Energy Sources, Wrocław University of Science and Technology, Wybrzeże Wyspiańskiego 27, 50-370 Wrocław, PolandThis study proposes an innovative system for recovering waste heat from exhaust air after a regenerative thermal oxidiser process, integrating a Carnot battery and photovoltaic (PV) modules. The Carnot battery incorporates an organic Rankine cycle (ORC) with a recuperator, thermal energy storage (TES), and heat pump. Waste heat is initially captured in TES, with additional energy extracted by a heat pump to increase the temperature of a secondary fluid, effectively charging TES from both direct and indirect sources. The stored heat enables electricity generation via ORC. The result of this study shows a heat pump COP between 2.55 and 2.87, the efficiency of ORC ranging from 0.125 to 0.155, and the power-to-power of the Carnot battery between 0.36 and 0.40. Moreover, PV generates 1.35 GWh annually, primarily powering the heat pump and ORC system pump. The proposed system shows a total annual net generation of 4.30 GWh. Economic evaluation across four configurations demonstrates favourable outcomes, with a return on investment between 25% and 160%. The economic evaluation examined configurations with and without the PV system and recuperation process in the ORC. Results indicate that incorporating the PV system and recuperator significantly increases power output, offering a highly viable and sustainable energy solution.https://www.mdpi.com/2076-3417/15/2/569thermodynamic cyclesphotovoltaicCarnot batteryenergy savingdecarbonisation
spellingShingle Putu Diah Prajna Paramita
Sindu Daniarta
Attila R. Imre
Piotr Kolasiński
Techno-Economic Analysis of Waste Heat Recovery in Automotive Manufacturing Plants
Applied Sciences
thermodynamic cycles
photovoltaic
Carnot battery
energy saving
decarbonisation
title Techno-Economic Analysis of Waste Heat Recovery in Automotive Manufacturing Plants
title_full Techno-Economic Analysis of Waste Heat Recovery in Automotive Manufacturing Plants
title_fullStr Techno-Economic Analysis of Waste Heat Recovery in Automotive Manufacturing Plants
title_full_unstemmed Techno-Economic Analysis of Waste Heat Recovery in Automotive Manufacturing Plants
title_short Techno-Economic Analysis of Waste Heat Recovery in Automotive Manufacturing Plants
title_sort techno economic analysis of waste heat recovery in automotive manufacturing plants
topic thermodynamic cycles
photovoltaic
Carnot battery
energy saving
decarbonisation
url https://www.mdpi.com/2076-3417/15/2/569
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AT sindudaniarta technoeconomicanalysisofwasteheatrecoveryinautomotivemanufacturingplants
AT attilarimre technoeconomicanalysisofwasteheatrecoveryinautomotivemanufacturingplants
AT piotrkolasinski technoeconomicanalysisofwasteheatrecoveryinautomotivemanufacturingplants