• Energy Research

The energy considered as waste heat in industrial furnaces owing to inefficiencies represents a substantial opportunity for recovery by means of thermal energy storage (TES) implementation. Although conventional systems based on sensible heat are used extensively, these systems involve technical limitations. Latent heat storage based on phase change materials (PCMs) results in a promising alternative for storing and recovering waste heat. Within this scope, the proposed PCM-TES allows for demonstrating its implementation feasibility in energy-intensive industries at high temperature range. The stored energy is meant to preheat the air temperature entering the furnace by using a PCM whose melting point is 885 °C. In this sense, a heat transfer model simulation is established to determine an appropriate design based on mass and energy conservation equations. The thermal performance is analysed for the melting and solidification processes, the phase transition and its influence on heat transference. Moreover, the temperature profile is illustrated for the PCM and combustion air stream. The obtained results prove the achievability of very high temperature levels (from 700 to 865 °C) in the combustion air preheating in a ceramic furnace; so corroborating an energy and environmental efficiency enhancement, compared to the initial condition presenting an air outlet at 650 °C.

Reductions in energy consumption, carbon footprint, equipment size, and cost are key objectives for the forthcoming energy-intensive industries roadmaps. In this sense, solutions such as waste heat recovery, which can be replicated into different sectors (e.g., ceramics, concrete, glass, steel, aluminium, pulp, and paper) are highly promoted. In this line, latent heat thermal energy storage (TES) contributes as an innovative technology solution to improve the overall system efficiency by recovering and storing industrial waste heat. To this end, phase-change material (PCM) selection is assisted through a decision-support system (DSS). A simplified tool based on the MATLAB® model, based on correlations among the most relevant system parameters, was developed to prove the feasibility of a cross-sectorial approach. The research work conducted a parametric analysis to assess the techno-economic performance of the PCM-TES solution under different working conditions and sectors. Additionally, a multicriteria assessment was performed comparing the tool outputs from metal alloys and inorganic hydrated PCM salts. Overall, the inorganic PCMs presented higher net economic and energy savings (up to 25,000 €/yr; 480 MWh/yr), while metal alloys involved promising results, shorter cycles, and competitive economic ratios; its commercial development is still limited.

Electricity from the combination of photovoltaic panels and wind turbines exhibits potential benefits towards the sustainable cities transition. Nevertheless, the highly fluctuating and intermittent character limits an extended applicability in the energy market. Particularly, batteries represent a challenging approach to overcome the existing constraints and to achieve sustainable urban energy development. On the basis of the market roll-out and level of technological maturity, five commercially available battery technologies are assessed in this work, namely, lead–acid, lithium manganese oxide, nickel–cadmium, nickel–metal hydride, and vanadium redox flow. When considering sustainable development, environmental assessments provide valuable information. In this vein, an environmental analysis of the technologies is conducted using a life cycle assessment methodology from a cradle-to-gate perspective. A comparison of the environmental burden of battery components identified vanadium redox flow battery as the lowest environmental damage battery. In terms of components, electrodes; the electrolyte; and the set of pumps, motors, racks, and bolts exhibited the greatest environmental impact related to manufacturing. In terms of materials, copper, steel, sulphuric acid, and vanadium were identified as the main contributors to the midpoint impact categories. The results have highlighted that challenging materials 4.0 are still needed in battery manufacturing to provide sustainable technology designs required to the future urban planning based on circular economy demands.

Abstract This paper provides quantitative information for energy consumption from four different industry sectors based on an energy analysis obtained by means of in-situ energy audits and complementary information. The latter information was taken from Saving Strategy and Energy Efficiency in Spain (Estrategia de Ahorro y Eficiencia Energetica en Espana 2004–2010, E4) documents and the 2009 Industrial Survey of Spain from the National Statistics Institute (Instituto Nacional de Estadistica, INE). The results show an estimate of energy consumption for each sector, namely Spanish food, drink and tobacco (9.6%), textile (4.5%), chemical (14.7%), and non-metallic mineral products (24.3%), as well as the degree of inefficiency for each, obtained by means of a stochastic frontier production function model. These results are combined with the energy consumption analysis to identify potential energy saving opportunities around 20.0% of the total energy consumption for all studied sectors. These energy saving opportunities are classified according to thermal or electrical energy consumption and percentage savings of the total energy consumption.

Abstract This paper presents a regression analysis of energy consumption in the banking sector. In our case study, the target area is the Spanish banking sector, for which we divide the available data into a prediction and a validation subset. Power models were developed using test data from 55 banks. From the analysis, three models were obtained; where the first proposed model can be used to predict the energy consumption of the whole banking sector, while the rest of the models estimate the energy consumption for branches with low winter climate severity (Model 2) and high winter climate severity (Model 3). Models 2 and 3 differ from the first model in that they need independent variables measured in situ. As a result, the uncertainty of the response variable in the function of the independent variables is reduced by 56.8% for the first model and by 65.2% and 68.5% for the second and third proposed models, respectively. The validation of the first model, which is the model with the lowest determination coefficient, shows that this model is appropriate for predicting the energy consumption of bank branches with good energy consumption performance and detecting inefficiencies in bank branches with poor energy consumption performance.

This work proposes an environmental analysis based on the life cycle assessment (LCA) methodology. LCA was applied to determine if energy savings are large enough to balance the environmental impact caused during phase change material (PCM) manufacture and its installation on tiles. Inputs and outputs of each management stage have been defined and the inventory emissions were calculated by SIMAPRO v 7.3.2. Emissions were classified into several impact categories; climate change, human toxicity, acidification, ozone depletion, particulate matter formation and eutrophication. Three commercial PCMs, evaluated using five different Spanish weather climates, were studied to explore a wide range of conditions. The main results conclude that the use of PCM can reduce the overall energy consumption and the environmental impacts. This reduction is strongly influenced by the climate conditions and the PCM introduced.

This study aims to analyse some of the most relevant issues that the energy intensive industry needs to face in order to improve its energy and environmental performance based on innovative retrofitting strategies. To this end, a case study based on the aluminium industry, as one of the most relevant within the European energy intensive industry has been thoroughly discussed. In particular, great efforts must be addressed to reduce its environmental impact; specifically focusing on the main stages concerning the manufacturing of an aluminium billet, namely alloy production, heating, extrusion and finishing. Hence, an innovative DC (direct current) induction technology with an expected 50% energy efficiency increase is used for retrofitting conventional techniques traditionally based on natural gas and AC (alternating current) induction. A life cycle assessment was applied to analyse three different scenarios within four representative European electricity mixes. The results reported reductions up to 8% of Green House Gases emissions in every country. France presented the best-case scenario applying only DC induction; unlike Greece, which showed around 150% increment. However, the suitability of the new DC induction technology depends on the electricity mix, the technological scenario and the environmental impact indicators. Finally, environmental external costs were assessed with comparison purposes to evaluate the increase of energy and environmental efficiency in existing preheating and melting industrial furnaces currently fed with natural gas.