Development of a Flexible Thermal Enhancement System Using Non-Recoverable Thermal Waste

• Grant number: 24/19919-9
• Support Opportunities: Research Grants - Innovative Research in Small Business - PIPE
• Start date: April 01, 2026
• End date: December 31, 2026
• Field of knowledge: Engineering - Mechanical Engineering - Thermal Engineering
• Principal Investigator: Hércules Rocha Montenegro
• Grantee: Hércules Rocha Montenegro
• Principal investigators: VIVALDO SILVEIRA JUNIOR

Abstract

In industrial processes, medium-temperature cooling waters are often treated as thermal waste that needs to be cooled before reuse. The common solution for this cooling is the use of evaporative cooling towers, which dissipate heat into the environment. Although this cooling method is simple and low-cost, it is limited by environmental conditions and results in the loss of potential energy. Given that an industrial plant has various processes utilizing heat transfer, this discarded energy could be harnessed for other purposes. Therefore, it is suggested to implement a machine that both cools the main process water and reuses the dissipated energy to heat another fluid to a higher temperature. One possible strategy is the application of a heat pump, with some adjustments and process integrations that need to be confirmed technically and economically. This proposal aims to develop a small-scale thermal system with dual application (dual thermal machine) to serve as a demonstrative showcase for integrating processes with simultaneous needs for low-temperature water cooling and reusing the dissipated energy to heat water to higher temperatures. Additionally, the machine will be powered by a combustion engine running on ethanol to provide flexibility in energy sources (electricity + ethanol). Subsequently, with this type of technically and economically viable integration, other applications with dual thermal benefits exceeding the investment could be realized. Thus, the deployment of this dual thermal machine and the demonstration of achieving appropriate thermal conditions for reuse and consumption waters will represent a process innovation, often not recognizing the obviousness of this integration, while also utilizing flexible and renewable energy, such as ethanol. (AU)