Development Of A New Micro CHP Pellet Stove Technology
Development of a New Micro CHP PelletStove TechnologyIngwald Obernberger, Gerhard Weiß,Manuel KösslEBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOS BIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 Graz, AustriaTEL.: 43 (316) 481300; FAX: 43 (316) 4813004E-MAIL: office@bios-bioenergy.atHOMEPAGE: http://www.bios-bioenergy.at
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazOutline Background and objectives Description of the new CHP pellet stove technology Stepwise optimization of the new CHP technology for pelletstoves Evaluation of test runs performed with the new CHPtechnology for pellet stoves Conclusions2
EBIIO M ASPCaMgRTWIEENH A L TERGIESNHGACKASC HET S C H AFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazBackground and objectives (I) Biomass based room heating systems are very common for spaceheating throughout Europe. In the recent 15 years pellet stoves becamemore and more popular due to their advantages regarding automatic control, user friendliness (automated ignition, easy and clean fuel handling) and low emissions in comparison to logwood stoves. However, the need of an external electric power supply to provideelectricity for ignition and stove operation is a disadvantage of pelletstoves especially with regard to fail-proof and independent heatingsystems. In order to enable the operation of a pellet stove without electric gridconnection, a new micro CHP technology for a pellet stove based on athermoelectric generator has been developed.3
EBIIO M ASPCaMgRTWIEENH A L TERGIESNHGACKASC HET S C H AFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazBackground and objectives (II) With thermoelectric generators (TEG) maintenance-free electric power canbe silently produced from heat. Thus, this technology is particularlysuitable to realise a grid-independent operation of stoves, which areusually used in residential areas (e.g. for heating of the living room). Project partner RIKA has worked in former projects on the development ofa TEG to cover the own-electricity consumption of a pellet stove. Thereby,the general applicability of the TEG technology for stoves has been provenand a pre-selection of thermoelectric modules (TEM, a TEG consists ofseveral thermoelectric modules connected in series) took place. Remaining open questions for a commercialisation of the technology: Number of TEMs needed to guarantee sufficient power production Positioning of the TEMs to get high and homogenous hot side temperatures Selection of an appropriate cooling system for the TEG Design of the pellet stove to guarantee a complete burnout of the flue gas before it iscooled by the TEG and to implement all components needed in the casing of the stove Optimisation of the power consumption of the pellet stove As low as possible additional costs for the TEG integration4
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazDescription of thenew CHP technology (I)General approach: During operation of the pellet stoveelectricity is produced by the TEG tooperate the stove and to charge anaccumulator.flue gascombustion airwater coolerTEGheat transferheat exchangerheat transfer The accumulator supplies electricityduring the next start-up for theignition and other power consumers(fan, fuel feeding, control system)until the TEG starts electricityproduction.pellet stovecombustion& heatexchangewood pellet The TEG is cooled by an appropriatewater circuit supplying room heaters. The new CHP pellet stove technology is based on a thermal stovecapacity of 10.5 kW.5
EBIIO M ASPCaMgRTWIEENH A L TERGIESNHGACKASC HET S C H AFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazDescription of thenew CHP technology (II) The principle of the TEG is based on the Seebeck effect, in which heat isdirectly converted into electricity by two connected and differently dopedsemiconductors placed at different temperatures.heattransferTEM with and without ceramic substrategeneral structure of a TEM The electric output of a TEM and thus the TEG is influenced by the type of the TEM the temperature difference between the cold and hot side of the TEM with rising temperature difference the electric output is increasing the cold side temperature of the TEM with a rising cold side temperature of the TEM the efficiency is decreasing Thus, a high temperature difference and a low cold side temperature ofthe TEM is aimed in order to achieve a high electric output of the TEG.6
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazStepwise optimization of the newCHP technology for pellet stovesMethodology: Transient system calculations for- definition of the meaningful number of TEMs- evaluation of different cooling options Definition of optimised system components enabling high efficiency, lowelectricity demand and low investment costs CFD (Computational Fluid Dynamics) based design of a pellet stove withintegrated TEG Construction of testing plants (2-stage approach) Performance of test runs, evaluation and stepwise optimisation of thetechnology7
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazTransient system calculations The main target of the transient system calculations was a realistic overalldynamic system modeling based on the given boundary conditionsregarding pellet stove operation, TEG and ambient. Thereby, 3 different cooling options have been modelled and evaluated: Due to the low and stable TEM/TEG cold side temperatures achievable,the water circuit is the most suitable cooling option. Furthermore, thiscooling option offers the possibility to heat an additional living room. In addition, the calculations pointed out that 10 – 12 TEMs are required toensure a sufficient power production during operation8
EBIIO M ASPCaMgRTWIEENH A L TERGIESNHGACKASC HET S C H AFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazCFD simulation: goalsPurpose of CFD-aided stove analysis and optimisation: Efficient CO burnout Efficient air staging Good flushing of the window by secondary air to ensure a clean window Reach high efficiency (acceptably low temperatures at stove outlet) Optimal positioning of TEMs Regarding high and homogeneous hot side temperatures Regarding allowable application temperatures Ensure low temperatures for the water pump and accumulator in the pelletstove casing9
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazCFD simulation results temperatures - cross sectional view Iso-surfaces of flue gas-, convection air- and stovetemperatures [ C] (nominal load)basic designtesting plant 1testing plant 2TEG with coolercast iron topcoverpost combustionchambermain combustionchamberheat exchangergrateash trayflue gas collectionchannel and fan10
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazCFD simulation results CO concentrations Iso-surfaces of CO concentrations [ppmv w. b.] in the flue gas in avertical cross section (nominal load)basic designtesting plant 1testing plant 211
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazCFD simulation results surface temperatures of TEG Iso-surfaces of surface temperatures [ C] on the TEMs in the TEG(nominal load)hot sidetesting plant 1testing plant 2Max. 302 Ccold sidetesting plant 2Max. 314 C12
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazTesting plants of thenew CHP technology Based on the development work a pre-optimised prototype of the microCHP system was constructed (testing plant 1) and comprehensive testruns have been performed to evaluate the performance of the pelletstove, the TEG as well as the cooling system. Based on the data andexperiences gained from thetest runs, the system hasbeen optimized and a second- close-to-the-product - testingplant was constructed andtested. In addition to the pellet stovea cooling system (watercircuit) was designed,constructed and tested.testing plant 2TEG cooling system13
IO M ASKASC HET S C H AFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 Graz According to the calculationsperformed 12 TEMs have beenimplemented in the testing plants. Depending on the temperaturedifference between cold and hot sideof the TEMs/TEG (which is directlycorrelated to the power of the pelletstove) the potential electric output is10 to 60 W. In addition the cold side temperatureof the TEMs/TEG has a stronginfluence on the efficiency and theelectric output. Thus, an efficientcooling is essential.7060Pre-calculations50Test run results403020100050100150200250Temperature difference TEG [ C]6030050250402003015020100TEG electric power [W]Temperature difference of the TEG [ C]10500060708090100110120Temperature difference TEG [ C]MgREvaluation of test runs with thenew CHP technology (I)Electric power TEG [W]CaTWIEPTEG electric power [W]EBIENH A L TERGIESNHGACCold side temperature of the TEG [ C]14
EBIIO M ASPCaMgRKASC HET S C H ATWIEEFEvaluation of test runs with thenew CHP technology (II)BIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazElectricity own consumption & electricity production: RIKA selected appropriate low voltage components (e.g. flue gas fan, ignitor) andoptimised the control system to reduce the electricity consumption. Based on the already very low electricity consumption of testing plant 1, for testingplant 2 a further reduction down to 9 W at nominal load and 5.5 W at part load(including the water pump for the TEG cooling circuit) could be achieved. The electric efficiency of theTEG based on the thermalinput is in the range of 1.4 to2.2% (related to the thermalpower input).Total power consumptionElectric capacity TEGEfficiency based on capacity502.5402.0301.5capacity to chargethe accumulator / toload external devices201.0100.50Electric efficiency [%] The electricity production of the TEG strongly rises from 10 W at 30% part load to50 W at nominal load.603.0Electric powerconsumption & production [W]NH A L TERGIESNHGAC2030405060708090Load of the pellet stove [%]10011015
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazEvaluation of test runs with thenew CHP technology (III)Energy balance: The biomass fuel input at nominal load is 2.4 kg/h or 11.8 kW (NCV). Based on the test run results, the thermal efficiency at nominal load is91% and rises at 30% part load up to 97%. At nominal load 8.4 kW of the useful heat is released by the pellet stoveand about 2.3 kW by the two radiators of the water cooling system toheat a second living room.Energy balanceBiomass fuel inputBiomass fuel power input (NCV)Thermal power combustion airHeat losses flue gasThermal power cooling system (water circuit)Thermal power pellet stove (radiation & convection air)Total thermal power pellet stove[kg/h][kW][kW][kW][kW][kW][kW]nominal 50% part 30% partloadloadload2,401,200,7211,785,893,540,05 0,03 ,44Share of the heat released by the water systemThermal efficiency (related to NCV)[%][%]21%91%21%95%21%97%Electric capacity TEGElectric efficiency (based on thermal input)[W][%]50,02,2%22,51,9%10,01,4%16
EBIIO M ASPCaMgRTWIEENH A L TERGIESNHGACKASC HET S C H AFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazEvaluation of test runs with thenew CHP technology (VI) Since in real life pellet stoves are operating at different loads and most of the timenot at stable conditions, the practical suitability of the new micro CHP technologyhas been evaluated based on a load cycle test developed for pellet stoves.Power consumption &production [W];Operation load [% ]120operating the stove and charging the accumulatorlight green areas show the potential to chargeexternal devices during the load cycle test10080160140120100608040604020008:0009:00TEG power [W]18020Flue gas temperature [ C] The load cycle includes four different load phases and three starts of the pelletstove and takes 8 h as a whole.light red areas show the electricity produced for010:0011:0012:00Total power consumption [W]13:0014:00Operation load [%]15:0016:00Flue gas at stove outlet [ C]Load cycle test according to the project bereal (www.bereal-project.eu) At the end of the load cycle test run the accumulator is again fully charged. In addition a potential of about 50 Wh to charge external devices is given duringthe load cycle test (although only short full load operation phases occur).17
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazConclusions With the new micro CHP technology based on a pellet stove and a TEGsystem, a renewable CO2-neutral room heating technology which canoperate off-grid has been developed. The TEG system is a wear- and maintenance-free as well as noiselesstechnology and thus ideally suitable for applications in living rooms. The electricity produced by the TEG system covers the energy demandfor operation and start-up of the pellet stove. The surplus electricityproduced can be used to charge mobile phones or other smallconsumers. In addition, due to the water cooling system, a second living room can beheated by the new technology. The final design of the new micro CHP technology and long-term testingof the new components is currently ongoing. Its market introduction isplanned by RIKA within 2018.18
EBIIO M ASPCaMgRKASC HET S C H ATWIEENH A L TERGIESNHGACFBIOENERGIESYSTEME GmbHHedwig-Katschinka-Straße 4, A-8020 GrazThe project was carried out in the core of the ERA-NET Bioenergyprogramme “7th Joint Call for Research and Development Proposals of theERA-NET Bioenergy”We gratefully acknowledge the Austrian climate and energy fund, forfunding the project “Small-scale BM based CHP” under its program“e!MISSION.at – 4th call”Thank you for your attentionContact:Prof. Dipl.-Ing. Dr. Ingwald ObernbergerHedwig-Katschinka-Straße 4, A-8020 Graz, AustriaTEL.: 43 (316) 481300; FAX: 43 (316) 4813004Email: obernberger@bios-bioenergy.atHOMEPAGE: http://www.bios-bioenergy.at
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