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Although some industrial sectors may offer greater opportunities for waste-heat recovery than others, most industrial sectors can reuse waste heat for preheating combustion air, preheating boiler feedwater, and preheating process load. For example, gas-to-gas heat exchangers can transfer heat from hot exhaust gases to the incoming combustion air. Similarly, gas-to-liquid heat exchangers can transfer waste heat from hot exhaust gases to boiler feedwater. Preheating load involves bringing high-temperature exhaust gases into direct contact with the relatively cooler load entering the process. This is a more cost-effective use of waste heat because it does not require the use of any heat exchanger. The integration of waste-heat recovery at a local process will have overall process implications for the entire facility. Fortunately, there are strategies, tools and methods available to help identify the most promising waste-heat recovery opportunities, while simultaneously ensuring optimal process integration and energy efficiency for the entire industrial facility. One of the most widely used process integration methods is pinch analysis. Pinch Analysis Pinch analysis was originally developed to determine optimal heat recovery between heat sources and heat loads, but is today also applied to combined heat and power systems, utility systems, distillation systems, reactor systems, hydrogen production, and even water management and wastewater treatment systems (Jolley 2006). There are four primary phases of pinch analysis in the design of waste-heat recovery systems for optimal process integration (Trivedi, Kirtan K., Fouche, Ed and Parmenter, Kelly E 2007): • Site survey: Data is collected for the process and utility system, with the primary focus on heating, cooling, boiling, and condensation needs. Every energy-containing non- product flow from the facility is identified first. Thereafter, accurate data about the original source of the waste-heat stream are gathered. Simulation data may be used when measured site data is inaccurate or unavailable. Finally, a heat balance on the process or system that produces the waste heat is completed. • Targeting: Targets for the minimum heating and cooling needs are established, and the maximum possible heat recovery is quantified. Practical, realistic targets are developed by taking constraints, such as difficulties in handling fluids and extended layout, into account. Comparison of practical targets with theoretically minimum values quantifies opportunities lost by the constraints. • Design: An initial heat exchanger network is established using commercial software packages. The basic design method focuses on minimum energy consumption while using the fewest possible heat exchanger units or minimal total heat transfer area. • Optimization: The initial heat exchanger network design is simplified and improved in terms of cost-effectiveness, and trade-offs between physical efficiency and costs are optimized. Significance of pinch temperature. Once the “hot” and “cold” streams are identified, the whole process can be plotted on a temperature-vs.-heat flow diagram (or Composite Curves) to examine what “hot” and “cold” streams can be matched via heat recovery (Figure 2, left). The Composite Curves identify the pinch temperature (the temperature where the two curves come closest together), the minimum external heating needs (QHmin), and the minimum external cooling needs © 2007 ACEEE Summer Study on Energy Efficiency in Industry 2-5PDF Image | Industrial Waste Heat Recovery Benefits and Recent Advancements in Technology and Applications
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