Feasibility study of modular energy conversion system as a gas let-down expander

An energy systems specialist is looking to create a more efficient, modular system for converting and recovering low-grade waste heat across the foundation sector

Recovering and reusing waste energy, be that gas, steam or heat, is a critical part of the blueprint for more efficient and sustainable foundation industries.

Currently, only a fraction of this energy is successfully captured and used, with current methods also often not sufficiently efficient to maximise the benefits of the process and taking a substantial amount of time to bring users a return on their financial outlay.

C2 Technology UK Ltd, backed by the Transforming Foundation Industries (TFI) challenge, designed a project application that identified an improved method of recovering low-power energy waste through a new proprietary system, bearing design and process that maximises the capture and reduces the energy input required.

"There are two elements to the new modular system that bring with them more effective results," says Dr Alexander Fedotov, Chief Operating Officer at C2 Technology UK Ltd, "Removing inefficient valves that can lose heat through leakage, as well as improving the necessary heating process by using existing wastewater instead of boiling water or electricity, gave us a more effective system – both in terms of cost and recovery results."

The project aimed to assess the feasibility of the concept in terms of product design and installation costs, as well as how long users would need to wait for the benefits to pay back their outlay. "We began to work with a successful paper business that already has an existing pressure system for energy recovery," adds Fedotov, "The project planned to run an information exchange programme on the current system and introduce gas consultants to monitor and provide data results. The costs and feasibility of re-routing wastewater and installing the modular system were also assessed."

As a result, the project successfully proved the concept. It developed knowledge and strategies for accommodating the system in different industrial settings and financing its use through different leasing or permanent installation plans.

Fedotov comments: "A big part of the project's aim was to prove the system's benefits and identify the hurdles and opportunities arising from different industrial uses. The fact that the modular design could be easily installed in a range of settings, with its safety certification already in place and the technology and energy savings inherent in the processes, meant we were in a strong place to complete the feasibility and focus on the practical and cost sides.

"The next steps for the project are to publish the latest results in 2023," Fedotov adds: "At this stage, a demo site will be created by installing the technology and running it for around a year, where potential investors and interested industries can see the system in action."