Supercritical Carbon Dioxide(S-CO2) Power Cycle for Waste Heat Recovery: a Review from Thermodynamic Perspective
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processes Review Supercritical Carbon Dioxide(s-CO2) Power Cycle for Waste Heat Recovery: A Review from Thermodynamic Perspective Liuchen Liu, Qiguo Yang and Guomin Cui * School of Energy and Power Engineering, University of Shanghai for Science and Technology, Shanghai 200093, China; [email protected] (L.L.); [email protected] (Q.Y.) * Correspondence: [email protected] Received: 11 October 2020; Accepted: 13 November 2020; Published: 15 November 2020 Abstract: Supercritical CO2 power cycles have been deeply investigated in recent years. However, their potential in waste heat recovery is still largely unexplored. This paper presents a critical review of engineering background, technical challenges, and current advances of the s-CO2 cycle for waste heat recovery. Firstly, common barriers for the further promotion of waste heat recovery technology are discussed. Afterwards, the technical advantages of the s-CO2 cycle in solving the abovementioned problems are outlined by comparing several state-of-the-art thermodynamic cycles. On this basis, current research results in this field are reviewed for three main applications, namely the fuel cell, internal combustion engine, and gas turbine. For low temperature applications, the transcritical CO2 cycles can compete with other existing technologies, while supercritical CO2 cycles are more attractive for medium- and high temperature sources to replace steam Rankine cycles. Moreover, simple and regenerative configurations are more suitable for transcritical cycles, whereas various complex configurations have advantages for medium- and high temperature heat sources to form cogeneration system. Finally, from the viewpoints of in-depth research and engineering applications, several future development directions are put forward. This review hopes to promote the development of s-CO2 cycles for waste heat recovery. Keywords: supercritical carbon dioxide power cycle; waste heat recovery; thermodynamic cycle 1. Introduction Efficient conversion and utilization of energy is an effective pathway to address energy shortage and environmental problems faced by mankind. However, several losses occur during the energy conversion process, starting from the primary energy carrier to the end-user, mainly in the form of waste heat. The waste heat discharged to the environment has high exergy value and also contains large quantities of pollutants, thus, contributing to global warming. The recovery of this waste heat for targeted use can significantly raise the process efficiency and reduce the primary energy consumption [1,2]. Such an energy-saving potential is particularly significant for industrial processes, thermal engines, and mechanical devices [3–5]. Take China as an example, the annual energy consumption of the industrial sector accounts for more than 70% of the total national energy consumption, of which at least 50% is converted to waste heat at different temperatures and with different carriers. The estimated waste heat in the cement, iron/steel, and glass industries in China, in 2016, were, 41.0 GWth, 2.9 GWth, and 1.8 GWth, respectively [3]. Generally speaking, there are many kinds and forms of waste heat resources. According to the investigation by Galanis et al. [6], waste energy is released from industrial processes to the environment via four main states of matter; namely, liquid streams at temperatures between 50 ◦C and 300 ◦C, Processes 2020, 8, 1461; doi:10.3390/pr8111461 www.mdpi.com/journal/processes Processes 2020, 8, 1461 2 of 18 Processes 2020, 8, x FOR PEER REVIEW 2 of 18 and 300 °C, exhaust at temperatures ranging between 150 °C to 800 °C, steam at temperatures ranging exhaust at temperatures ranging between 150 ◦C to 800 ◦C, steam at temperatures ranging from from 100 °C to 250 °C, as well as the process gases and vapors within a temperature range of 80 °C to 100 ◦C to 250 ◦C, as well as the process gases and vapors within a temperature range of 80 ◦C to 500 °C. Furthermore, low-temperature(<350 °C) waste heat accounts for the majority in most end-use 500 ◦C. Furthermore, low-temperature (<350 ◦C) waste heat accounts for the majority in most end-use energyenergy sectors. sectors. AsAs shownshown inin FigureFigure1 ,1, evaluations evaluations reveal reveal that that 63% 63% of of the the waste waste heat heat streams streams arise arise at at temperatures below 100 °C, and the largest proportion of which is produced by the electricity sector, temperatures below 100 ◦C, and the largest proportion of which is produced by the electricity sector, followedfollowed by by the the commercial commercial and and transportation transportation sector sector [ 1[1].]. FigureFigure 1. 1.Sectoral Sectoral sharesshares of of worldwide worldwide waste waste heat heat distribution distribution [ 1[1].]. FromFrom a a thermodynamic thermodynamic point point of of view,view, energy energy from from waste waste heat heat cancan bebe recoveredrecovered inin variousvarious ways.ways. DirectDirect heatheat exchangeexchange cancan taketake placeplace betweenbetween wastewaste heatheat andand otherother fluids,fluids, namelynamely thethe heatheat transfertransfer fluidsfluids for for the the heating heating and and cooling cooling process process [ 7[7,8].,8]. Conversion Conversion ofof waste waste heat heat into into useful useful power power is is done done usingusing a a thermodynamic thermodynamic cycle. cycle. TheThe wastewaste heatheat cancan bebe usedused asas aa heatheat source,source, i.e.,i.e., thethe high-temperaturehigh-temperature side,side, which which is is used used to heatto heat the workingthe working fluid fluid to obtain to obtain a gas phasea gas of phase certain of temperature certain temperature and pressure. and Thispressure. working This fluid, working or the fluid, waste or the heat waste fluid heat itself, fluid can itself, be used can be to used perform to perform expansion expansion work [ 9work,10]. Another[9,10]. Another method method is to raise is to the raise temperature the temperature of the waste of the heat waste to aheat required to a required value using value a using heat pump a heat forpump special for special applications applications such as such distributed as distribute energyd energy systems systems [11,12]. [11,12]. These These diverse diverse pathways pathways face challenges,face challenges, such as such the low-grade as the low-grade and fluctuation and andfluctuation intermittency and intermittency of heat sources, of ine heatfficiencies sources, in theinefficiencies energy conversion in the energy process, conversion and cascade process, utilization and cascade of diff erentutilization energy of sources. different energy sources. 2.2. BarriersBarriers toto WasteWaste Heat Heat Recovery Recovery UsingUsing waste waste heat heat as as an an energyenergy source source is is basedbased onon manymany aspects,aspects, whichwhich areare elaboratedelaborated asas follows:follows: ManyMany factorsfactors makemake wastewaste heatheat recoveryrecovery veryvery didifficult,fficult, suchsuch asas operating operating principleprinciple ofof heatheat recoveryrecovery facilities,facilities, user user demand, demand, and and characteristics characteristics of of the the source source of of the the waste waste heat. heat. Each Each method method of of waste waste heat heat recoveryrecovery is is posed posed with with diff erentdifferent problems, problems, thus, thethus, technologies the technologies face a number face a ofnumber barriers. of Abarriers. graphical A representationgraphical representation of the various of the energy various conversion energy conver pathwayssion forpathways waste heatfor waste is shown heat in is Figureshown2 in. Waste Figure heat2. Waste is known heat is to known mainly to originate mainly originate from two from types two of sources,types of i.e.,sources, fossil i.e., fuel fossil and fuel renewable and renewable energy. Mostenergy. of theMost waste of the heat waste from heat fossil from fuel fossil involves fuel involves industrial industrial processes processes while renewable while renewable energy canenergy be usedcan be directly used directly through through an air pre-heater, an air pre-heater, waste heat waste boiler, heat and boiler, economizer, and economizer, and a small and part a small of them part needof them to go need through to go athrough thermal a power thermal cycle power before cycle being before used being [13]. used This [13]. is one This of is the one main of the reasons main forreasons the temperature for the temperature grade diversification grade diversification of waste of heat waste resources. heat resources. Meanwhile, Meanwhile, as mentioned as mentioned above, theabove, diverse the formsdiverse of forms waste of heat waste recovery heat recovery technologies technologies depend ondepend the specific on the energyspecific form energy needed form byneeded the end-user. by the end-user. At this point,At this the point, limitation the limitati of spaceon of forspace equipment for equipment as well as as well the as economic the economic and and environmental boundaries should be taken into account. These abovementioned issues make an efficient waste heat recovery challenging. Processes 2020, 8, 1461 3 of 18 environmental boundaries should be taken into account. These abovementioned issues make an Processesefficient 2020 waste, 8, x heatFOR PEER recovery REVIEW challenging. 3 of 18 Figure 2. WasteWaste heat recovery from various heat sources [[13].13]. From a technical perspective, the following aspectsaspects need to bebe highlighted.highlighted.