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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MDPI AG
2025-01-01
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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 |
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| 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. |
| format | Article |
| id | doaj-art-7cb97a6c33154aa6b5df1d29e564ba7a |
| institution | Kabale University |
| issn | 2076-3417 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
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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 |
| work_keys_str_mv | AT putudiahprajnaparamita technoeconomicanalysisofwasteheatrecoveryinautomotivemanufacturingplants AT sindudaniarta technoeconomicanalysisofwasteheatrecoveryinautomotivemanufacturingplants AT attilarimre technoeconomicanalysisofwasteheatrecoveryinautomotivemanufacturingplants AT piotrkolasinski technoeconomicanalysisofwasteheatrecoveryinautomotivemanufacturingplants |