D.3.4 Design review of the hybrid heat pump

Executive Summary

This document is the deliverable “D3.4 – Design review of the hybrid heat pump” in the European project “HYCOOL – Industrial Cooling through Hybrid system based on Solar Heat” (hereinafter also referred to as “HYCOOL”, project reference: 792073). HyCool Project Mission is increasing the current use of Solar Heat in Industry Processes, and to do so the project proposes the coupling of a new Fresnel CSP Solar thermal collectors (FCSP) system with specially build Hybrid Heat Pumps (HHP) (a “two in one” combination of adsorption and compressor-based heat pumps) for a wider output temperature range (Solar Heating & Cooling –SHC-), and a wide range of design and operational configurations to increase the potential implementation of the proposed Solar Heat in industrial environments. The solutions encompassed in the project will be implemented and tested in operational processes in two different pilot cases in the food and chemical industry. The food case pilot is hosted by Bo de Deb. which represents a small food industry in a high solar irradiation area with cooling needs in the production processes. Here the industrial cold installation is necessary for the good preservation of the product. The chemical case pilot targets industries with several processes in high solar irradiation areas with steam and cooling needs. This pilot is hosted by Givaudan where the cold installation makes use of a brine chiller to keep the water entering the liquid ring of the vacuum pumps at 7.C.

The purpose of this deliverable is to describe the key findings of the review process, which focuses on the design of the Hybrid Heat Pump. This report contains the findings with regard to control strategy, the interconnection of the heat pumps, selection of the suitable adsorbent and refrigerant, as well as an optimal size of the HHP.

D.1.1 Interim first year report on project management

Executive Summary

The present deliverable D1.1 Interim first-year report on project management, hereafter named interim report (IR), contains the necessary information for the Hycool to evaluate the state of implementation of the project, mainly the work plan, the timely review of the scheduled milestones and deliverables will allow an efficient project implementation as well as concrete options for adjustments of management procedures, compliance with the provisions of the EC, finances, and monitors each partner’s costs, the financial situation of the project and all administrative matters. The technical part contains a concise statement of the tasks undertaken and a forecast for the next reporting period. Any problems encountered during the period and possible deviations from project plans. This deliverable set by the Consortium, is the first IR planed in the WP1 at M12, jointly with the other two IR planned at M18 and M36, at the end of the project. These deliverables are differentiated from the periodic reporting (PR) set by INEA and planned at M18 and M36. Basically, the PR includes the detailed description of the technical work carried out by beneficiaries, the work performed by the work package, the impact, and finally the deviations and the full financial information. This report covers the first period from M1 (May 2018) to M12 (April 2019).

We have been showcased @CORDIS_EU

Our project aiming to increase the use of solar heat in industrial processes has been featured at cordis.europa.eu, the European Commission’s primary source of results, news, and information on EU-funded research projects. The article shows how we are boosting the concept on the cheap and easy-to-install linear Fresnel system, which basically consists of many mirrors in parallel rows, that imitate a large Fresnel Lens, to augment solar energy acquisition. This concentrated solar power system (CSP) is coupled with tailor-made hybrid heat pumps (HHPs) that enable “both industrial heating and cooling powered by the sun” as our project coordinator, Silvia Jané, has explained.
Quoting the article:
“At the Spanish production site of consortium partner Givaudan, a flavors and fragrances company, the HyCool concept has been applied to several processes with either heating or cooling needs. Givaudan’s current cold installation makes use of a glycolic water chiller to keep the water entering the liquid ring of the vacuum pumps at 7 °C, with a thermal demand of 125.5kW. ”For the use cases considered, the electrical consumption of the compression chiller will be reduced by 29 % (spring) and 44 % (summer), respectively, by using HyCool technology,” says Jané This efficiency gain is even higher if compared to common refrigeration systems”.
We are advancing this technology and systems to promote energy efficiency for industries.

Three insights on the development of the hybrid heat pump

The hybrid heat pump constitutes one of the core elements of the HyCool solution for solar cooling in industry and, therefore, its optimal design is crucial to achieving high performance of the overall system. Since the very beginning of the project, the Fahrenheit team has been working on a prototype of the hybrid heat pump with the goal of obtaining highest efficiency while keeping the machine simple and reliable. In the early spring of 2019, the first prototype HyCool XHHP01 was ready for testing. The results of the tests performed by CNR have shown a very good performance of the prototype and have indicated a few areas, which still needed improvement. Currently, the Fahrenheit team is making use of the time left before the installation of the pilot sites to optimize the functionalities of the hybrid heat pump. Three members of the team explain to us the general concept of the hybrid heat pump, how they want to optimize the prototype, and what challenges are still ahead of them.

After the tests at CNR’s premises in Italy, the prototype HyCool XHHP01 came back to Germany, where the Fahrenheit engineers are working on further improvements in the design of the hybrid heat pump.

 

The hybrid heat pump constitutes one of the core elements of the HyCool solution for solar cooling in industry and, therefore, its optimal design is crucial to achieving high performance of the overall system.

 

Eliza Nowak, Project Engineer at Fahrenheit GmbH, on the general concept of the hybrid heat pump

The term “hybrid” refers to a combination of two or more interconnected and co-operating heat pumps based on different principles of operation. In our case, the developed prototype consists of an adsorption and a compression heat pump connected in such a way that the evaporator of the adsorption unit cools down the condenser of the compression one. This lowers the condensation temperature below the one resulting from the outdoor conditions. Lower condensation temperature means higher EER (Energy Efficiency Ratio – ratio of the delivered cooling capacity to the consumed electrical power) of the compression chiller. Of course, to make this layout feasible, the savings of the electrical power consumption of the compressor due to higher EER should be higher than the additional power consumption of the adsorption unit and its auxiliaries.

Doreen Acker works on the changes in the control software of the hybrid heat pump.

Doreen Acker, Software Developer at Fahrenheit GmbH, on the prototype optimization

In terms of the control software optimization, we are implementing two changes in the HyCool XHHP01 prototype. The first one is the introduction of a free cooling mode, to allow the use of low external temperatures for cooling of the compression unit’s condenser. In brief, in the free cooling mode the condensation heat of the compression chiller is dissipated directly to the ambient air via the dry cooler. If the outdoor temperatures are low enough to ensure the condensing temperature of the compression chiller as low as or lower than with the use of the adsorption chiller, which happens mostly in winter and during night time, the system will operate more efficiently in the free cooling mode. The operation of the system resembles the standard operation of the compression chiller and saves the electrical power needed to drive the circulating pumps of the adsorption chiller. Thanks to the clever hydraulic connections in the adsorption unit, we can implement this new operation mode through a software update without the need to rebuild anything in hydraulics. The second change is the optimized start-up procedure. After the tests performed by the colleagues from CNR, they suggested that the compression unit should be started when the temperature in the cold water circuit of the adsorption unit reaches a specified threshold. In this way, we will ensure favourable conditions for the operation of the compression unit at all times.

René Weinitschke, After Sales & Factory Service Engineer at Fahrenheit GmbH, on the data logging and Cloud solutions

René Weinitschke is responsible for the implementation of Cloud solutions for data logging.

In order to evaluate the performance of the hybrid heat pump, we have to perform measurements and collect meaningful data. Some of the measurements will be carried out by the main control system based on the sensors installed on the pipelines but there are also quite a few sensors installed inside the prototype. The values from these sensors will not be sent to the main control system; rather we plan to collect them in the Cloud. We have not used this technology so far, but its implementation in our commercial projects is one of our priorities. It will not only help our After Sales services, but also contribute to our technology development. HyCool is a great opportunity for us to test this solution! From the beginning, we have to place great emphasis on the data security, especially because the pilot plants will be installed in “real-life” factories.

According to the current execution plan, the optimized prototype of the hybrid heat pump is going to be delivered to the Bo de Debó demo site in October 2019. After proper installation and commissioning, the operation of the hybrid heat pump will be monitored for 12 consecutive months. Based on the collected data the Fahrenheit team will evaluate its performance. It is expected that due to the optimization measures implemented, the prototype will show even better performance than what was achieved during the first tests at CNR.