it useful again.

When there is a waste of energy or a heat stream that is not

recovered, a heat exchanger can covert that heat stream into something that we
can use.

Industrial applications :
• Process liquid or gas cooling
• Process or refrigerant vapor or steam condensing
• Process liquid, steam or refrigerant evaporation
• Process heat removal and preheating of feed water
• Thermal energy conservation efforts, heat recovery
• Compressor, turbine and engine cooling, oil and jacket water
• Hydraulic and lube oil cooling etc.

43
Chapter 3
Thermal Energy Management
3.1 Thermal Energy Storage
What is Thermal Storage?
Thermal energy storage (TES) is a new application of an old idea that can
cut air conditioning energy costs in half. Air conditioning system during daytime
hours is the largest single contributor to electrical peak demand. In the afternoon,
as more air conditioning is needed to maintain comfortable temperatures, the
increased demand for electricity adds to the load already created by lighting,
operating equipment, computers and many other sources.
This requires the electric suppliers to bring additional, more costly
generating equipment on line to handle this increased demand. Commercial
users, whose large air conditioning loads greatly contribute to the need for these
seldomly used generating stations, are charged more for this "On Peak" energy,
either in the form of higher energy charges (kWh) or a "Demand Charge" which is
based on their highest on-peak demand (kW) for electricity. The "On-Peak"
demand charge is normally based on the electricity required (in kW) over a
specified time period, usually 15 minutes, assessed on a monthly or yearly basis.
In Thailand energy charge for TOU rate on the peak period (09.00-22.00 Monday
through Friday ) is 2.695 B/kWh while off peak period ( 22.00-09.00 Monday
through Friday and National Holidays) is 1.1914 B/kWh and demand charge
during on peak period is 132.93 B/kW while off peak period is no charge. For
TOD rate demand charge during on peak period (18.00-21.30 all days ) is 285.05
B/kW and energy charge is 1.7034 B/kWh.
Thermal Energy Storage (TES) System is a technology which shifts
electric load to off-peak hours which will not only significantly lower energy and
demand charges during the air conditioning season, but can also lower total
energy usage (kWh) as well. It uses a standard chiller to produce solid ice at night
during off-peak periods when the building’s electrical loads are at a minimum. The
electric supplier's generating capacity is also typically under-utilized at night and,
consequently, its rates are lowest then. The ice is built and stored in modular ice
tanks to provide cooling to help meet the building’s air conditioning load
requirement the following day allowing chillers to be downsized or turned off.

44
 Ice Bank Systems not only can cut operating costs in half but they can also
substantially reduce capital outlays when systems are suitably designed for new
commercial and industrial buildings. Engineers can specify half-size chillers
operating 20-24 hours a day rather than full-size chillers operating only 10 or 12
hours per day. In retrofit applications, an Ice Bank TES System can often provide
cooling for an addition or increased loads to a building without adding chiller
capacity.

Figure 3-17 Thermal storage system on charge cycle

Figure 3-18 Thermal storage system on discharge cycle

45
 Figure 3-19 Thermal storage system on bypass cycle

How to application?
Thermal energy storage is suitable for buildings or factories which use
large amount of Air Conditioning system and use TOU or TOD Tariff rate.

3.2 Heat Reclaim Technology

A refrigeration heat reclaim (RHR) water heating system links two common
functions in commercial buildings to reduce purchased energy consumption and
achieve cost savings. A refrigeration heat reclaim water heating system harvests
heat that would normally be rejected through refrigeration system condensers and
applies the heat for water heating. See Figure 1. Refrigeration heat reclaim water
heating has the advantages of relatively low cost and simplicity. The primary
limitation of refrigeration heat reclaim water heating systems is the fact that heat
is available only when the refrigeration system is in operation. However, in many
applications heat storage capacity and the operating diversity of heat source
equipment remove this concern.
A refrigeration heat reclaim device is simply a refrigerant-to-water heat
exchanger installed between the host refrigeration system's compressor and
condenser. On heat pumps, the heat exchanger is installed between the
compressor and the reversing valve. Water is circulated through one side of the

46
heat exchanger and hot refrigerant gas from the compressor is routed through the
other side. Heat is transferred from the hot refrigerant gas to the water.

Most refrigeration heat reclaim devices are desuperheaters. Superheat

refers to heat stored in the refrigerant vapor when it is heated above the
temperature at which it evaporates for a given pressure. See Figure 3. Acting as
a desuperheater, a heat reclaim device cools the refrigerant only to the saturation
point; no condensing takes place in the desuperheater. Under typical conditions a
desuperheater can remove about 10 to 30% of the total heat that would have
been rejected by the condenser.

A heat reclaim device may also be designed to do condensing rather than

just desuperheating. More heat can be extracted, but at a lower temperature.
However, most refrigeration heat reclaim equipment manufacturers have
intentionally prevented condensing to avoid problems with host equipment
operation. Excessive subcooling (reduction of liquid refrigerant temperature below
the saturation point) in the condenser at low outdoor temperature is the concern.
With excessive subcooling, problems can occur with low compressor head
pressure, improper expansion device operation from inadequate pressure drop,
and liquid slugging in the compressor.

Most refrigeration heat reclaim units are designed for retrofit installation. Since
installation involves cutting into the sealed refrigerant system, a qualified
refrigeration mechanic should do the work. The effect of the installation on any
warranties for the refrigeration system should be investigated. Some
manufacturers of air conditioners and refrigeration systems place limitations on
warranties if heat reclaim systems are installed.

3.3 Hot Water from Air Compressor System

Heat Recovery and Compressed Air Systems
As much as 80-93% of the electrical energy used by an industrial air compressor
is converted into heat. In many cases, a properly designed heat recovery unit can

47
recover anywhere from 50-90% of this available thermal energy and put it to
useful work heating air or water.

Typical uses for recovered heat include supplemental space heating, industrial
process heating, water heating, makeup air heating, and boiler makeup water
preheating. Recoverable heat from a compressed air system is not, however,
normally hot enough to be used to produce steam directly.

Heat recovery systems are available for both air- and water-cooled compressors.

Heat Recovery with Air-Cooled Rotary Screw Compressors

Heating Air.Air-cooled packaged rotary screw compressors are very amenable

to heat recovery for space heating or other hot air uses. Ambient atmospheric air
is heated by passing it across the system's aftercooler and lubricant cooler,
where it extracts heat from both the compressed air and the lubricant that is
used to lubricate and cool the compressor.

Since packaged compressors are typically enclosed in cabinets and already

include heat exchangers and fans, the only system modifications needed are the
addition of ducting and another fan to handle the duct loading and to eliminate
any back pressure on the compressor cooling fan. These heat recovery systems
can be modulated with a simple thermostatically-controlled hinged vent. When
heating is not required -- such as in the summer months -- the hot air can be
ducted outside the building. The vent can also be thermostatically regulated to
provide a constant temperature for a heated area.

Hot air can be used for space heating, industrial drying, preheating aspirated air
for oil burners, or any other application requiring warm air. As a rule of thumb,
approximately 50,000 Btu/hour of energy is available for each 100 cfm of
capacity (at full-load). Air temperatures of 30 to 40oF above the cooling air inlet
temperature can be obtained. Recovery efficiencies of 80-90% are common.

Caution should be applied because if the supply air for the compressor is not
from outside, and the recovered heat is used in another space, you can

48
decrease the static pressure in the cabinet and reduce the efficiency of the
compressor. If outside air is used, some return air may be required to avoid
damaging the compressor with below freezing air.

Heating Water.Using a heat exchanger, it is also possible to extract waste heat

from the lubricant coolers found in packaged water-cooled reciprocating or rotary
screw compressors and produce hot water. Depending on design, heat
exchangers can produce non-potable (gray) or potable water. When hot water is
not required, the lubricant is routed to the standard lubricant cooler.

Hot water can be used in central heating or boiler systems, industrial cleaning
processes, plating operations, heat pumps, laundries, or any other application
where hot water is required. Heat exchangers also offer an opportunity to
produce hot air and hot water, and allow the operator some ability to vary the hot
air/hot water ratio.

Heat Recovery with Water-Cooled Compressors

Heat recovery for space heating is not as common with water-cooled

compressors because an extra stage of heat exchange is required and the
temperature of the available heat is lower. Since many water-cooled
compressors are quite large, however, heat recovery for space heating can be
an attractive opportunity. Recovery efficiencies of 50-60% are typical.

49