IDEAS home Printed from https://ideas.repec.org/a/eee/appene/v225y2018icp782-796.html
   My bibliography  Save this article

Integrating cogeneration and intermittent waste-heat recovery in food processing: Microturbines vs. ORC systems in the coffee roasting industry

Author

Listed:
  • Pantaleo, Antonio M.
  • Fordham, Julia
  • Oyewunmi, Oyeniyi A.
  • De Palma, Pietro
  • Markides, Christos N.

Abstract

Coffee roasting is a highly energy intensive process wherein a large quantity of heat is discharged from the stack at medium-to-high temperatures. Much of the heat is released from the afterburner, which is required to remove volatile organic compounds and other pollutants from the flue gases. In this work, intermittent waste-heat recovery via thermal energy storage (TES) and organic Rankine cycles (ORCs) is compared to combined heat and power (CHP) based on micro gas-turbines (MGTs) for a coffee roasting plant. With regard to the former, a promising solution is proposed that involves recovering waste heat from the flue gas stream by partial hot-gas recycling at the rotating drum coffee roaster, and coupling this to a thermal store and an ORC engine for power generation. The two solutions (CHP + MGT prime mover vs. waste-heat recovery + ORC engine) are investigated based on mass and energy balances, and a cost assessment methodology is adopted to compare the profitability of three system configurations integrated into the selected roasting process. The case study involves a major Italian roasting plant with a 3,000 kg per hour coffee production capacity. Three options are investigated: (i) intermittent waste-heat recovery from the hot flue-gases with an ORC engine coupled to a TES system; (ii) regenerative topping MGT coupled to the existing modulating gas burner to generate hot air for the roasting process; and (iii) non-regenerative topping MGT with direct recovery of the turbine outlet air for the roasting process. The results show that the profitability of these investments is highly influenced by the natural gas and electricity prices and by the coffee roasting production capacity. The CHP solution via an MGT appears as a more profitable option than waste-heat recovery via an ORC engine primarily due to the intermittency of the heat-source availability and the high electricity cost relative to the cost of natural gas.

Suggested Citation

  • Pantaleo, Antonio M. & Fordham, Julia & Oyewunmi, Oyeniyi A. & De Palma, Pietro & Markides, Christos N., 2018. "Integrating cogeneration and intermittent waste-heat recovery in food processing: Microturbines vs. ORC systems in the coffee roasting industry," Applied Energy, Elsevier, vol. 225(C), pages 782-796.
  • Handle: RePEc:eee:appene:v:225:y:2018:i:c:p:782-796
    DOI: 10.1016/j.apenergy.2018.04.097
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S030626191830655X
    Download Restriction: Full text for ScienceDirect subscribers only

    File URL: https://libkey.io/10.1016/j.apenergy.2018.04.097?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Oyeniyi A. Oyewunmi & Christos N. Markides, 2016. "Thermo-Economic and Heat Transfer Optimization of Working-Fluid Mixtures in a Low-Temperature Organic Rankine Cycle System," Energies, MDPI, vol. 9(6), pages 1-21, June.
    2. Oyewunmi, Oyeniyi A. & Kirmse, Christoph J.W. & Haslam, Andrew J. & Müller, Erich A. & Markides, Christos N., 2017. "Working-fluid selection and performance investigation of a two-phase single-reciprocating-piston heat-conversion engine," Applied Energy, Elsevier, vol. 186(P3), pages 376-395.
    3. Milani, Massimo & Montorsi, Luca & Terzi, Stefano, 2017. "Numerical analysis of the heat recovery efficiency for the post-combustion flue gas treatment in a coffee roaster plant," Energy, Elsevier, vol. 141(C), pages 729-743.
    4. Domenico Borello & Antonio M. Pantaleo & Michele Caucci & Benedetta De Caprariis & Paolo De Filippis & Nilay Shah, 2017. "Modeling and Experimental Study of a Small Scale Olive Pomace Gasifier for Cogeneration: Energy and Profitability Analysis," Energies, MDPI, vol. 10(12), pages 1-17, November.
    5. Freeman, James & Hellgardt, Klaus & Markides, Christos N., 2015. "An assessment of solar-powered organic Rankine cycle systems for combined heating and power in UK domestic applications," Applied Energy, Elsevier, vol. 138(C), pages 605-620.
    6. Fernández, Inmaculada & Renedo, Carlos J. & Pérez, Severiano F. & Ortiz, Alfredo & Mañana, Mario, 2012. "A review: Energy recovery in batch processes," Renewable and Sustainable Energy Reviews, Elsevier, vol. 16(4), pages 2260-2277.
    7. Oyewunmi, Oyeniyi A. & Taleb, Aly I. & Haslam, Andrew J. & Markides, Christos N., 2016. "On the use of SAFT-VR Mie for assessing large-glide fluorocarbon working-fluid mixtures in organic Rankine cycles," Applied Energy, Elsevier, vol. 163(C), pages 263-282.
    8. Kirmse, Christoph J.W. & Oyewunmi, Oyeniyi A. & Taleb, Aly I. & Haslam, Andrew J. & Markides, Christos N., 2017. "A two-phase single-reciprocating-piston heat conversion engine: Non-linear dynamic modelling," Applied Energy, Elsevier, vol. 186(P3), pages 359-375.
    9. Lecompte, Steven & Huisseune, Henk & van den Broek, Martijn & Vanslambrouck, Bruno & De Paepe, Michel, 2015. "Review of organic Rankine cycle (ORC) architectures for waste heat recovery," Renewable and Sustainable Energy Reviews, Elsevier, vol. 47(C), pages 448-461.
    10. Fang, Hao & Xia, Jianjun & Zhu, Kan & Su, Yingbo & Jiang, Yi, 2013. "Industrial waste heat utilization for low temperature district heating," Energy Policy, Elsevier, vol. 62(C), pages 236-246.
    11. Markides, Christos N. & Solanki, Roochi & Galindo, Amparo, 2014. "Working fluid selection for a two-phase thermofluidic oscillator: Effect of thermodynamic properties," Applied Energy, Elsevier, vol. 124(C), pages 167-185.
    12. Freeman, James & Hellgardt, Klaus & Markides, Christos N., 2017. "Working fluid selection and electrical performance optimisation of a domestic solar-ORC combined heat and power system for year-round operation in the UK," Applied Energy, Elsevier, vol. 186(P3), pages 291-303.
    13. Christoph J.W. Kirmse & Oyeniyi A. Oyewunmi & Andrew J. Haslam & Christos N. Markides, 2016. "Comparison of a Novel Organic-Fluid Thermofluidic Heat Converter and an Organic Rankine Cycle Heat Engine," Energies, MDPI, vol. 9(7), pages 1-26, June.
    14. Steven Lecompte & Oyeniyi A. Oyewunmi & Christos N. Markides & Marija Lazova & Alihan Kaya & Martijn Van den Broek & Michel De Paepe, 2017. "Case Study of an Organic Rankine Cycle (ORC) for Waste Heat Recovery from an Electric Arc Furnace (EAF)," Energies, MDPI, vol. 10(5), pages 1-16, May.
    15. Naghavi, M.S. & Ong, K.S. & Badruddin, I.A. & Mehrali, M. & Silakhori, M. & Metselaar, H.S.C., 2015. "Theoretical model of an evacuated tube heat pipe solar collector integrated with phase change material," Energy, Elsevier, vol. 91(C), pages 911-924.
    16. Markides, Christos N. & Smith, Thomas C.B., 2011. "A dynamic model for the efficiency optimization of an oscillatory low grade heat engine," Energy, Elsevier, vol. 36(12), pages 6967-6980.
    17. Stamp, Jane & Majozi, Thokozani, 2011. "Optimum heat storage design for heat integrated multipurpose batch plants," Energy, Elsevier, vol. 36(8), pages 5119-5131.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Herrando, María & Pantaleo, Antonio M. & Wang, Kai & Markides, Christos N., 2019. "Solar combined cooling, heating and power systems based on hybrid PVT, PV or solar-thermal collectors for building applications," Renewable Energy, Elsevier, vol. 143(C), pages 637-647.
    2. White, M.T. & Oyewunmi, O.A. & Chatzopoulou, M.A. & Pantaleo, A.M. & Haslam, A.J. & Markides, C.N., 2018. "Computer-aided working-fluid design, thermodynamic optimisation and thermoeconomic assessment of ORC systems for waste-heat recovery," Energy, Elsevier, vol. 161(C), pages 1181-1198.
    3. Le Brun, Niccolo & Simpson, Michael & Acha, Salvador & Shah, Nilay & Markides, Christos N., 2020. "Techno-economic potential of low-temperature, jacket-water heat recovery from stationary internal combustion engines with organic Rankine cycles: A cross-sector food-retail study," Applied Energy, Elsevier, vol. 274(C).
    4. Li, Xiaoya & Xu, Bin & Tian, Hua & Shu, Gequn, 2021. "Towards a novel holistic design of organic Rankine cycle (ORC) systems operating under heat source fluctuations and intermittency," Renewable and Sustainable Energy Reviews, Elsevier, vol. 147(C).
    5. Dimitris Katsaprakakis & Vasilis Kagiamis & George Zidianakis & Luca Ambrosini, 2019. "Operation Algorithms and Computational Simulation of Physical Cooling and Heat Recovery for Indoor Space Conditioning. A Case Study for a Hydro Power Plant in Lugano, Switzerland," Sustainability, MDPI, vol. 11(17), pages 1-36, August.
    6. Chatzopoulou, Maria Anna & Lecompte, Steven & Paepe, Michel De & Markides, Christos N., 2019. "Off-design optimisation of organic Rankine cycle (ORC) engines with different heat exchangers and volumetric expanders in waste heat recovery applications," Applied Energy, Elsevier, vol. 253(C), pages 1-1.
    7. Konečná, Eva & Teng, Sin Yong & Máša, Vítězslav, 2020. "New insights into the potential of the gas microturbine in microgrids and industrial applications," Renewable and Sustainable Energy Reviews, Elsevier, vol. 134(C).
    8. Catrini, P. & Panno, D. & Cardona, F. & Piacentino, A., 2020. "Characterization of cooling loads in the wine industry and novel seasonal indicator for reliable assessment of energy saving through retrofit of chillers," Applied Energy, Elsevier, vol. 266(C).
    9. Emadi, Mohammad Ali & Chitgar, Nazanin & Oyewunmi, Oyeniyi A. & Markides, Christos N., 2020. "Working-fluid selection and thermoeconomic optimisation of a combined cycle cogeneration dual-loop organic Rankine cycle (ORC) system for solid oxide fuel cell (SOFC) waste-heat recovery," Applied Energy, Elsevier, vol. 261(C).
    10. Tobias Popp & Andreas P. Weiß & Florian Heberle & Julia Winkler & Rüdiger Scharf & Theresa Weith & Dieter Brüggemann, 2021. "Experimental Characterization of an Adaptive Supersonic Micro Turbine for Waste Heat Recovery Applications," Energies, MDPI, vol. 15(1), pages 1-20, December.
    11. Dahan Sun & Zhongyan Liu & Hao Zhang & Xin Zhang, 2024. "Performance Analysis of a New Cogeneration System with Efficient Utilization of Waste Heat Resources and Energy Conversion Capabilities," Energies, MDPI, vol. 17(13), pages 1-28, July.
    12. Acha, Salvador & Le Brun, Niccolo & Damaskou, Maria & Fubara, Tekena Craig & Mulgundmath, Vinay & Markides, Christos N. & Shah, Nilay, 2020. "Fuel cells as combined heat and power systems in commercial buildings: A case study in the food-retail sector," Energy, Elsevier, vol. 206(C).
    13. Florian Raab & Lennart Böse & Harald Klein & Frank Opferkuch, 2024. "Steam Storage Rankine Cycle for Unutilized Applications in Distributed High-Temperature Waste Heat Recovery," Energies, MDPI, vol. 17(4), pages 1-26, February.
    14. van Kleef, Luuk M.T. & Oyewunmi, Oyeniyi A. & Markides, Christos N., 2019. "Multi-objective thermo-economic optimization of organic Rankine cycle (ORC) power systems in waste-heat recovery applications using computer-aided molecular design techniques," Applied Energy, Elsevier, vol. 251(C), pages 1-1.
    15. Sanjay Mukherjee & Abhishek Asthana & Martin Howarth & Jahedul Islam Chowdhury, 2020. "Techno-Economic Assessment of Waste Heat Recovery Technologies for the Food Processing Industry," Energies, MDPI, vol. 13(23), pages 1-26, December.
    16. Couvreur, Kenny & Beyne, Wim & De Paepe, Michel & Lecompte, Steven, 2020. "Hot water storage for increased electricity production with organic Rankine cycle from intermittent residual heat sources in the steel industry," Energy, Elsevier, vol. 200(C).
    17. Lamidi, Rasaq. O. & Jiang, L. & Pathare, Pankaj B. & Wang, Y.D. & Roskilly, A.P., 2019. "Recent advances in sustainable drying of agricultural produce: A review," Applied Energy, Elsevier, vol. 233, pages 367-385.
    18. Xu, Jingyuan & Luo, Ercang & Hochgreb, Simone, 2020. "Study on a heat-driven thermoacoustic refrigerator for low-grade heat recovery," Applied Energy, Elsevier, vol. 271(C).

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Steven Lecompte & Oyeniyi A. Oyewunmi & Christos N. Markides & Marija Lazova & Alihan Kaya & Martijn Van den Broek & Michel De Paepe, 2017. "Case Study of an Organic Rankine Cycle (ORC) for Waste Heat Recovery from an Electric Arc Furnace (EAF)," Energies, MDPI, vol. 10(5), pages 1-16, May.
    2. White, M.T. & Oyewunmi, O.A. & Chatzopoulou, M.A. & Pantaleo, A.M. & Haslam, A.J. & Markides, C.N., 2018. "Computer-aided working-fluid design, thermodynamic optimisation and thermoeconomic assessment of ORC systems for waste-heat recovery," Energy, Elsevier, vol. 161(C), pages 1181-1198.
    3. van Kleef, Luuk M.T. & Oyewunmi, Oyeniyi A. & Markides, Christos N., 2019. "Multi-objective thermo-economic optimization of organic Rankine cycle (ORC) power systems in waste-heat recovery applications using computer-aided molecular design techniques," Applied Energy, Elsevier, vol. 251(C), pages 1-1.
    4. Chatzopoulou, Maria Anna & Markides, Christos N., 2018. "Thermodynamic optimisation of a high-electrical efficiency integrated internal combustion engine – Organic Rankine cycle combined heat and power system," Applied Energy, Elsevier, vol. 226(C), pages 1229-1251.
    5. Emadi, Mohammad Ali & Chitgar, Nazanin & Oyewunmi, Oyeniyi A. & Markides, Christos N., 2020. "Working-fluid selection and thermoeconomic optimisation of a combined cycle cogeneration dual-loop organic Rankine cycle (ORC) system for solid oxide fuel cell (SOFC) waste-heat recovery," Applied Energy, Elsevier, vol. 261(C).
    6. Nikunj Gangar & Sandro Macchietto & Christos N. Markides, 2020. "Recovery and Utilization of Low-Grade Waste Heat in the Oil-Refining Industry Using Heat Engines and Heat Pumps: An International Technoeconomic Comparison," Energies, MDPI, vol. 13(10), pages 1-29, May.
    7. Sindhu Preetham Burugupally & Leland Weiss, 2018. "Power Generation via Small Length Scale Thermo-Mechanical Systems: Current Status and Challenges, a Review," Energies, MDPI, vol. 11(9), pages 1-22, August.
    8. Oyewunmi, Oyeniyi A. & Kirmse, Christoph J.W. & Haslam, Andrew J. & Müller, Erich A. & Markides, Christos N., 2017. "Working-fluid selection and performance investigation of a two-phase single-reciprocating-piston heat-conversion engine," Applied Energy, Elsevier, vol. 186(P3), pages 376-395.
    9. Ramos, Alba & Chatzopoulou, Maria Anna & Freeman, James & Markides, Christos N., 2018. "Optimisation of a high-efficiency solar-driven organic Rankine cycle for applications in the built environment," Applied Energy, Elsevier, vol. 228(C), pages 755-765.
    10. Chatzopoulou, Maria Anna & Lecompte, Steven & Paepe, Michel De & Markides, Christos N., 2019. "Off-design optimisation of organic Rankine cycle (ORC) engines with different heat exchangers and volumetric expanders in waste heat recovery applications," Applied Energy, Elsevier, vol. 253(C), pages 1-1.
    11. Pantaleo, Antonio M. & Camporeale, Sergio M. & Sorrentino, Arianna & Miliozzi, Adio & Shah, Nilay & Markides, Christos N., 2020. "Hybrid solar-biomass combined Brayton/organic Rankine-cycle plants integrated with thermal storage: Techno-economic feasibility in selected Mediterranean areas," Renewable Energy, Elsevier, vol. 147(P3), pages 2913-2931.
    12. Pantaleo, Antonio M. & Camporeale, Sergio M. & Miliozzi, Adio & Russo, Valeria & Shah, Nilay & Markides, Christos N., 2017. "Novel hybrid CSP-biomass CHP for flexible generation: Thermo-economic analysis and profitability assessment," Applied Energy, Elsevier, vol. 204(C), pages 994-1006.
    13. Fabio Fatigati & Diego Vittorini & Yaxiong Wang & Jian Song & Christos N. Markides & Roberto Cipollone, 2020. "Design and Operational Control Strategy for Optimum Off-Design Performance of an ORC Plant for Low-Grade Waste Heat Recovery," Energies, MDPI, vol. 13(21), pages 1-23, November.
    14. Tan, Jingqi & Luo, Jiaqi & Huang, Jiale & Wei, Jianjian & Jin, Tao, 2020. "A closed two-phase thermofluidic oscillator with zeotropic mixtures for low-grade heat recovery," Energy, Elsevier, vol. 211(C).
    15. Tan, Jingqi & Wei, Jianjian & Jin, Tao, 2020. "Electrical-analogy network model of a modified two-phase thermofluidic oscillator with regenerator for low-grade heat recovery," Applied Energy, Elsevier, vol. 262(C).
    16. Simpson, Michael C. & Chatzopoulou, Maria Anna & Oyewunmi, Oyeniyi A. & Le Brun, Niccolo & Sapin, Paul & Markides, Christos N., 2019. "Technoeconomic analysis of internal combustion engine – organic Rankine cycle systems for combined heat and power in energy-intensive buildings," Applied Energy, Elsevier, vol. 253(C), pages 1-1.
    17. Wang, Kai & Dubey, Swapnil & Choo, Fook Hoong & Duan, Fei, 2017. "Thermoacoustic Stirling power generation from LNG cold energy and low-temperature waste heat," Energy, Elsevier, vol. 127(C), pages 280-290.
    18. Christoph J.W. Kirmse & Oyeniyi A. Oyewunmi & Andrew J. Haslam & Christos N. Markides, 2016. "Comparison of a Novel Organic-Fluid Thermofluidic Heat Converter and an Organic Rankine Cycle Heat Engine," Energies, MDPI, vol. 9(7), pages 1-26, June.
    19. Alexander Kronberg & Maxim Glushenkov & Sander Roosjen & Sascha Kersten, 2023. "Isobaric Expansion Engines–Compressors: Thermodynamic Analysis of Multistage Vapor Driven Compressors," Energies, MDPI, vol. 16(19), pages 1-15, September.
    20. Li, Xiaoya & Xu, Bin & Tian, Hua & Shu, Gequn, 2021. "Towards a novel holistic design of organic Rankine cycle (ORC) systems operating under heat source fluctuations and intermittency," Renewable and Sustainable Energy Reviews, Elsevier, vol. 147(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:appene:v:225:y:2018:i:c:p:782-796. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/wps/find/journaldescription.cws_home/405891/description#description .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.