Techno-economic analysis of integrated energy systems for spray drying applications

Project Description

Process heat represents 37% of the total industrial energy demand in the EU, with a significant share of fossil fuel-based energy sources. In this context, the food and beverage sector constitutes one of the largest consumers of process heat in the temperature range between 100-500°C and therefore is a key sector for decarbonization. The dairy processing units are highly energy intensive, and around 12.000 of such facilities are spread across the EU.

Electrification and heat upgrade technologies are becoming increasingly relevant as one of the ways to meet the high thermal energy demand required by the industrial sector. Nowadays, efficient electrification technologies (high temperature heat pumps) are commercially available for heat deliveries up to about 120-140 °C. The next step toward a broader decarbonization of the industrial sector is the development and deployment of efficient electrified solutions for flexible waste heat upgrade including thermal energy storages, innovative high temperature heat pumps, and maximization of the direct RES based energy contribution and waste heat recovery.

This work presents a techno-economic assessment of a high-temperature Stirling heat pump retrofitting a milk powder production plant operating on gas boilers. Stirling cycles can offer higher temperature lifts and reliably operate up to 200°C, functioning on closed heated regenerative gas cycles. The Stirling heat pump investigated works with helium (R704) which is an inert, non-toxic refrigerant with zero ozone depletion potential and null global warming potential, therefore being ideal for food processing applications where product quality is indispensable. Refrigerants that could potentially compromise production by contaminating the process must be avoided.

Objective and goals

The primary objective of the thesis is to develop a consolidated techno-economic assessment model integrating high temperature heat pump technology for the specific study case of spray drying case in a milk powder factory.

Methodology

• The work should develop the heat pump module and its integration to the process diagram of the milk powder factory.

• Main KPIs are: Steam production (kg/h), LCoH, CAPEX, OPEX and carbon emissions.

Main Deliverables

The main deliverables of the project include:

• Final project report and presentation comprising description of project, literature review, integrated solution definition via specific layout and operation descriptions, techno-economic performance assessment and system optimization, and final suggestions.

• TEA models: models and user guidelines / instructions.

Duration

January/Febraury (lastest), 2026 – June 2026 (flexible) – 6 months duration

Main Supervisors

Examiner