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Generating electricity from industrial waste heat

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Language: en

00:00:01.190
German industrial output competitive
00:00:05.059 00:00:05.069 products and waste heat every year some
00:00:09.379 00:00:09.389 200 billion kilowatt hours of unused
00:00:11.780 00:00:11.790 waste heat are dumped into the
00:00:13.610 00:00:13.620 environment that amounts to nearly the
00:00:18.650 00:00:18.660 entire energy consumption of the German
00:00:20.900 00:00:20.910 state of hessin if that energy were put
00:00:29.300 00:00:29.310 to use it would also reduce large
00:00:31.880 00:00:31.890 amounts of co2 emissions in addition the
00:00:37.910 00:00:37.920 German Environment Agency estimates that
00:00:40.069 00:00:40.079 German companies could save 3 to 6
00:00:42.440 00:00:42.450 billion euros a year in energy costs it
00:00:51.709 00:00:51.719 makes a lot of sense to tap into the
00:00:53.840 00:00:53.850 enormous potential of this form of power
00:00:56.209 00:00:56.219 production that's already being done at
00:01:04.009 00:01:04.019 the bish tine company in the city of
00:01:05.929 00:01:05.939 hagen in north rhine-westphalia the
00:01:08.870 00:01:08.880 company processes sheet metal here
00:01:11.440 00:01:11.450 custom-made for clients in the furniture
00:01:13.820 00:01:13.830 tool-making and automobile industries
00:01:19.260 00:01:19.270 this Stein uses a special production
00:01:21.790 00:01:21.800 process called cold rolling special
00:01:26.140 00:01:26.150 scaffolds move rolls of sheet metal
00:01:28.180 00:01:28.190 known as coils into a rolling mill a
00:01:32.520 00:01:32.530 force of more than 600 tons is exerted
00:01:36.070 00:01:36.080 onto the coils the coils are fed through
00:01:39.310 00:01:39.320 the rollers and pressed to the desired
00:01:41.830 00:01:41.840 thickness after cold rolling the
00:01:47.140 00:01:47.150 material is hardened
00:01:50.830 00:01:50.840 the sheet metal can only be formed again
00:01:53.469 00:01:53.479 and further processed after its
00:01:56.010 00:01:56.020 recrystallized an annealing oven is
00:02:01.240 00:02:01.250 heated to several hundred degrees
00:02:02.859 00:02:02.869 Celsius a crane stacks several coils on
00:02:07.330 00:02:07.340 top of each other on a pedestal a
00:02:10.920 00:02:10.930 protective cover is placed over the
00:02:13.240 00:02:13.250 stack then protective gas fills the
00:02:17.770 00:02:17.780 space between the coils and the cover
00:02:21.509 00:02:21.519 the gas optimizes the heat exchange
00:02:24.520 00:02:24.530 during the annealing process and
00:02:26.110 00:02:26.120 protects the metal from unwanted
00:02:27.850 00:02:27.860 chemical reactions while one pedestal is
00:02:33.370 00:02:33.380 placed in the oven another has just
00:02:35.589 00:02:35.599 finished the annealing phase the heat
00:02:38.259 00:02:38.269 cover is removed the gas burner heated
00:02:41.470 00:02:41.480 the protective cover to more than 800
00:02:43.600 00:02:43.610 degrees Celsius the whole system has to
00:02:47.920 00:02:47.930 cool down before the cover and coils can
00:02:50.500 00:02:50.510 be removed
00:02:51.980 00:02:51.990 [Music]
00:02:57.690 00:02:57.700 in a cellar below the oven the
00:03:00.300 00:03:00.310 protective gas gives off its heat with
00:03:02.610 00:03:02.620 the help of heat exchangers thermal oil
00:03:06.120 00:03:06.130 is heated to some 250 degrees Celsius
00:03:11.610 00:03:11.620 in this way the company uses the waste
00:03:14.610 00:03:14.620 heat that results from the annealing
00:03:16.199 00:03:16.209 process necessary for recrystallization
00:03:19.759 00:03:19.769 in a container this heat is transformed
00:03:23.640 00:03:23.650 into the most valuable form of energy
00:03:25.860 00:03:25.870 electric power normally hot steam
00:03:32.460 00:03:32.470 measuring several hundred degrees
00:03:33.869 00:03:33.879 Celsius is used to produce power but now
00:03:37.530 00:03:37.540 an innovative organic rankine cycle
00:03:40.190 00:03:40.200 called an o RC unit can produce power
00:03:43.410 00:03:43.420 using only 250 degree thermal oil
00:03:53.950 00:03:53.960 through a heat exchanger the oils
00:03:56.740 00:03:56.750 thermal energy is transferred to fluid
00:03:58.930 00:03:58.940 bio ethanol which immediately evaporates
00:04:01.690 00:04:01.700 at this high temperature the bio ethanol
00:04:04.900 00:04:04.910 steam has 35 bar of pressure and drives
00:04:08.140 00:04:08.150 a special steam engine the construction
00:04:12.760 00:04:12.770 resembles a conventional combustion
00:04:14.710 00:04:14.720 engine but no combustion takes place in
00:04:18.070 00:04:18.080 the cylinder head
00:04:20.670 00:04:20.680 the compressed bioethanol steam enters
00:04:23.540 00:04:23.550 gradually it expands in the cylinder
00:04:27.540 00:04:27.550 putting pressure on the pistons a total
00:04:31.469 00:04:31.479 of 12 cylinders drive the engines
00:04:33.450 00:04:33.460 crankshaft after discharge the steam
00:04:39.120 00:04:39.130 only has one bar of pressure and
00:04:41.040 00:04:41.050 measures some 100 degrees Celsius that's
00:04:45.029 00:04:45.039 enough to heat water to around 75
00:04:47.249 00:04:47.259 degrees Celsius over another heat
00:04:49.469 00:04:49.479 exchanger
00:04:52.870 00:04:52.880 then the bio ethanol is compressed again
00:04:56.120 00:04:56.130 and the whole cycle starts from the
00:04:58.370 00:04:58.380 beginning
00:05:04.860 00:05:04.870 this RC unit can generate electricity
00:05:08.010 00:05:08.020 using waste heat at a relatively low
00:05:10.140 00:05:10.150 temperature the level of efficiency
00:05:13.950 00:05:13.960 reaches around fifteen percent in
00:05:17.630 00:05:17.640 addition the heated water can be used
00:05:20.550 00:05:20.560 for other purposes directional midni
00:05:24.840 00:05:24.850 multi-shot students might expect the
00:05:26.340 00:05:26.350 unit to pay for itself in five to six
00:05:28.410 00:05:28.420 years the waste heat generated by the
00:05:31.260 00:05:31.270 ORAC process saves both electricity and
00:05:34.320 00:05:34.330 gas use it to heat buildings and
00:05:37.440 00:05:37.450 production processes and the cooling
00:05:39.720 00:05:39.730 process speeds up our production so on
00:05:43.790 00:05:43.800 first the waste energy is used for the
00:05:46.890 00:05:46.900 annealing process then for power
00:05:49.530 00:05:49.540 production and finally for heating the
00:05:51.870 00:05:51.880 building's in that order this cascading
00:05:56.640 00:05:56.650 energy use is extremely efficient the
00:06:03.180 00:06:03.190 production of limestone gravel for the
00:06:05.280 00:06:05.290 cement industry also takes place in
00:06:07.680 00:06:07.690 stages
00:06:18.670 00:06:18.680 this quarry in Bavaria produces material
00:06:21.460 00:06:21.470 for a cement factory in nearby avoid off
00:06:25.650 00:06:25.660 besides lime and clay limestone is the
00:06:29.110 00:06:29.120 most important raw material in cement
00:06:31.360 00:06:31.370 production
00:06:38.010 00:06:38.020 each year this quarry near the Austrian
00:06:40.680 00:06:40.690 border produces some 1 million tonnes of
00:06:43.350 00:06:43.360 material that is essential for the
00:06:45.360 00:06:45.370 construction industry
00:06:49.730 00:06:49.740 a rotary kiln is located at the center
00:06:52.760 00:06:52.770 of the facility it's more than five
00:06:55.700 00:06:55.710 meters wide and some 70 meters long raw
00:07:00.890 00:07:00.900 materials and other additives flow
00:07:02.870 00:07:02.880 through the pipe they're heated into
00:07:05.510 00:07:05.520 what's called cement clinker the process
00:07:09.950 00:07:09.960 is run from a control room underneath
00:07:14.779 00:07:14.789 the kiln a 200,000 degree flame provides
00:07:18.350 00:07:18.360 the necessary energy at the other end
00:07:24.320 00:07:24.330 waste gas flows upwards through a heat
00:07:27.379 00:07:27.389 exchange tower meanwhile the raw
00:07:30.830 00:07:30.840 materials and additives drop downward
00:07:33.290 00:07:33.300 through the tower in the opposite
00:07:34.969 00:07:34.979 direction
00:07:36.070 00:07:36.080 that way the hot waste gas heats up the
00:07:40.249 00:07:40.259 materials pre-warming them the waste gas
00:07:44.990 00:07:45.000 exiting the tower still has a
00:07:46.670 00:07:46.680 temperature of more than 400 degrees
00:07:48.680 00:07:48.690 Celsius and is extremely dust-laden
00:07:52.600 00:07:52.610 until now this energy was only partly
00:07:55.939 00:07:55.949 used in a new waste heat boiler it now
00:08:00.920 00:08:00.930 gives off most of its thermal energy
00:08:02.930 00:08:02.940 into a steam pipeline
00:08:06.600 00:08:06.610 the dust-laden gas flows through the
00:08:09.790 00:08:09.800 boiler the boiler contains a large
00:08:13.330 00:08:13.340 number of pipes steam flows through the
00:08:17.350 00:08:17.360 pipes in the opposite direction of the
00:08:19.270 00:08:19.280 waste gas that raises the steams
00:08:22.240 00:08:22.250 temperature from 190 to some 400 degrees
00:08:26.140 00:08:26.150 Celsius the dust carried by the waste
00:08:32.530 00:08:32.540 gas settles on the surface of the pipes
00:08:34.930 00:08:34.940 a special hammer mechanism on the floor
00:08:39.520 00:08:39.530 of the boiler strikes a role of poles
00:08:41.880 00:08:41.890 causing the pipes to vibrate the dust
00:08:45.430 00:08:45.440 falls to the floor this mechanism
00:08:49.150 00:08:49.160 prevents the dust from interfering with
00:08:51.280 00:08:51.290 the boilers operation
00:08:53.730 00:08:53.740 00:08:57.620 00:08:57.630 thanks to this technology steam can even
00:09:01.170 00:09:01.180 be won from extremely dust-laden
00:09:03.150 00:09:03.160 industrial gas 400° steam flows through
00:09:07.320 00:09:07.330 the pipe to a turbine the turbine has a
00:09:11.040 00:09:11.050 power output of up to seven megawatts
00:09:13.590 00:09:13.600 and uses a generator to produce
00:09:15.930 00:09:15.940 electricity normally these turbines use
00:09:21.000 00:09:21.010 steam with temperatures of more than 800
00:09:23.250 00:09:23.260 degrees Celsius but the innovative waste
00:09:26.310 00:09:26.320 heat boiler allows for the use of much
00:09:28.590 00:09:28.600 lower temperatures
00:09:33.870 00:09:33.880 you happy I'm Stan good power power
00:09:36.540 00:09:36.550 consumption is 100 Giga watt hours at
00:09:38.970 00:09:38.980 this location we produce 30 percent of
00:09:41.580 00:09:41.590 that or 30 gigawatt hours on our own
00:09:45.230 00:09:45.240 that equals some 8,000 households in
00:09:48.240 00:09:48.250 Germany and it saves 80,000 tons of co2
00:09:51.330 00:09:51.340 and Germany's power mix the electricity
00:09:57.450 00:09:57.460 is mostly used on location in Nagoya
00:09:59.490 00:09:59.500 Dorf
00:10:00.680 00:10:00.690 but the potential use of industrial
00:10:03.000 00:10:03.010 waste heat in Germany is huge whether
00:10:07.890 00:10:07.900 power is produced by an ORAC unit or a
00:10:10.620 00:10:10.630 conventional steam turbine waste heat
00:10:13.680 00:10:13.690 power generation technologies can be
00:10:15.570 00:10:15.580 used in a variety of sectors
00:10:21.590 00:10:21.600 according to the German Environment
00:10:23.700 00:10:23.710 Agency the country could generate 10 to
00:10:26.220 00:10:26.230 15 terawatt-hours of electricity this
00:10:28.500 00:10:28.510 way each year that roughly equals the
00:10:31.620 00:10:31.630 yearly power consumption of the German
00:10:33.690 00:10:33.700 capital Berlin and it could go a long
00:10:38.700 00:10:38.710 way toward further optimizing German
00:10:41.250 00:10:41.260 industrial output

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