IOT BASED SMART POWER GENERATION FROM INDUSTRIAL WASTE HEAT USING HEAT PIPE AND THERMOELECTRIC GENERATOR
In majority of the industries, about one third of the all-out thermal energy involved is delivered to the environment as waste heat. The current energy conversion frameworks are not proficient to avoid such heat losses. With the serious concerns about regular ascents in the oil prices,
2025-06-28 16:28:19 - Adil Khan
IOT BASED SMART POWER GENERATION FROM INDUSTRIAL WASTE HEAT USING HEAT PIPE AND THERMOELECTRIC GENERATOR
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryIn majority of the industries, about one third of the all-out thermal energy involved is delivered to the environment as waste heat. The current energy conversion frameworks are not proficient to avoid such heat losses. With the serious concerns about regular ascents in the oil prices, society has directed concentration toward advancements which can limit fossil fuel consumption and limit the greenhouse effect. The energy or power generated relies upon how much thermal energy used and wasted. The recuperation of modern waste heat can save money and gives a productive energy practice to industry. However, most of the industrial waste heat is of low grade and at low temperature. Such kind of waste heat is hard to recover or to use with an ordinary heat engines, for example a steam turbine in a power plant. It is exceptionally attractive to design a heat transfer device which works passively in order that very little temperature drop can be accomplished during the recovery of low temperature waste heat.
The motive of designing this system is to develop a thermal to work conversion system for simultaneous heat recovery and power generation following passive heat transfer method. This system is assigned as a heat pipe thermoelectric generator (HP-TEG). The essential idea of the system comprises of thermoelectric generators (TEGs) sandwiched between two heat pipes, one connected with the hot side of the TEG, and the other is connected with the cold side of the TEG.
The thesis presents an efficient design process, a theoretical modeling, experimental examination, and cost-benefit investigation for a real system. The proposed framework has the potential at the same time to recover waste heat and produce electrical power in an altogether passive system with no auxiliary powers.
We will incorporate IOT in our system. It is the inter communication between device to device or machine learning connected to internet with embedded technology systems using wireless sensors, actuators which is remotely controlled, monitored ,and optimized by the user for automation and is designated as internet of things (IOT).
Project Objectives ObjectiveThe expectation that the recuperation of low-grade waste heat from industry can minimize the greenhouse effect and can further improve the related overall thermal energy conversion efficiency has encouraged us to design and develop a prototype to utilize this cost free energy. There is enormous amount of low-grade (<150°C) heat depleted to the environmental elements from various industrial cycles. In most of cases, recovery of this low-temperature waste heat is unreasonable and uneconomical.
The aim of this project is to develop a passive heat transfer and heat to work conversion system for simultaneous heat recovery and power generation. This will be connected to internet with embedded technology systems using wireless sensors, actuators and can be remotely controlled, monitored, and optimized by the user for automation and is designated as internet of things (IOT).
Project Implementation MethodThe experimental prototype rig will incorporates a TEG sandwiched between two heat pipes. One heat pipe comes from cold air duct and another heat pipe module comes from hot air duct (heated by electric heater) to achieve the temperature gradient for thermoelectricity generation. The condenser section of heat pipe 1 is thermally attached at the hot side of the TEG as a heater, and the evaporator section of heat pipe 2 provides the cooling role.
The heat transfer device contains of two sets of rectangular finned tube heat pipes that are attached to copper blocks. In order to minimize the interfacial thermal resistance of the heat transfer device and TEG, lead free galvanizing solder is used to thermally bond the heat pipes and copper blocks. These copper blocks then attached to hot and cold sides of TEG, and transferring the temperature from heat pipes to thermoelectric generators (TEGs). This will be connected to internet with embedded technology systems using wireless sensors, actuators and can be remotely controlled, monitored, and optimized by the user for automation and is designated as internet of things (IOT).
Benefits of the ProjectIn 2019, the total global energy consumption was approximately 120 million tonnes of oil equivalent (Mtoe), 40% the rate of growth observed in 2018. With the rapid growth in the industrial sector of developing nations over the last decade, the industrial sector has consumed energy at approximately 2852 mtoe. Approximately 33% of the total thermal energy consumed in industry is released as waste heat. The vast majority of the heat energy released by industry is recognized as low-grade heat. This kind of waste heat has a little work delivering potential for temperatures underneath 230°C, and this suggests a low energy density. Which make it almost impossible to recover it and convert it into electrical energy through conventional systems for example steam or gas turbine. However there are some other heat to electricity conversion systems, such as the Organic-Rankine Cycle (ORC) and the Kalina cycle. But they have much complex design and they require rotatory parts which can cause wear and tear which require high investment cost. Therefore these systems are not economically suitable. On account of the limitations related with low degree waste heat, it is attractive to have a passive strategy to change over this thermal power into electrical energy. A heat pipe is probably the best gadget for heat recovery applications as it has an extensive scope of working temperature and a high heat conductance. As it have no moving parts, compact structure, small pressure drop, and light in weight.
Direct heat to-electrical energy conversion of waste thermal energy can likewise be achieved by utilizing a TEG. The TEG can produce electrical power by placing it between a heat source and heat sink. The fundamental phenomenon is known as the Seebeck effect. A TEG is suitable for conversion of low temperature heat into electrical energy. It has small and compact size and requires almost no maintenance.
Technical Details of Final DeliverableThe experimental prototype rig will incorporates a TEG sandwiched between two heat pipes. One heat pipe comes from cold air duct and another heat pipe module comes from hot air duct (heated by electric heater) to achieve the temperature gradient for thermoelectricity generation. The condenser section of heat pipe 1 is thermally attached at the hot side of the TEG as a heater, and the evaporator section of heat pipe 2 provides the cooling role.
The heat transfer device contains of two sets of rectangular finned tube heat pipes that are attached to copper blocks. In order to minimize the interfacial thermal resistance of the heat transfer device and TEG, lead free galvanizing solder is used to thermally bond the heat pipes and copper blocks. These copper blocks then attached to hot and cold sides of TEG, and transferring the temperature from heat pipes to thermoelectric generators (TEGs). This will be connected to internet with embedded technology systems using wireless sensors, actuators and can be remotely controlled, monitored, and optimized by the user for automation and is designated as internet of things (IOT).
Final Deliverable of the Project HW/SW integrated systemCore Industry Energy Other Industries Manufacturing Core Technology Internet of Things (IoT)Other Technologies Clean TechSustainable Development Goals Affordable and Clean Energy, Industry, Innovation and InfrastructureRequired Resources
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 69300 | |||
| Air duct | Equipment | 2 | 2500 | 5000 |
| Electric Heater | Equipment | 1 | 5500 | 5500 |
| Variable Fan | Equipment | 2 | 1500 | 3000 |
| Heat Pipe Module | Equipment | 16 | 2000 | 32000 |
| Aluminum Fins | Equipment | 2 | 4500 | 9000 |
| Sensor | Equipment | 6 | 550 | 3300 |
| solder | Equipment | 1 | 3000 | 3000 |
| Thermal paste | Equipment | 5 | 500 | 2500 |
| Travelling | Miscellaneous | 1 | 6000 | 6000 |