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Industrial Waste Heat Recovery Benefits and Recent Advancements in Technology and Applications

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Industrial Waste Heat Recovery Benefits and Recent Advancements in Technology and Applications ( industrial-waste-heat-recovery-benefits-and-recent-advanceme )

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• May reduce air emission treatment costs: The cost of treatment of air pollutants may be significantly reduced by waste-heat recovery from exhaust gases in those facilities that rely on incinerators to decompose gaseous or vaporous air pollutants; • May improve product quality: The use of heat pumps for lumber drying typically provides better quality dried lumber and higher yields. Economics of Waste-Heat Recovery The economic potential of waste-heat recovery systems depends on the capital recovery, which, in turn, depends on the annual fuel savings. Fuel savings can be difficult to predict because they depend on the time distribution of waste-heat and heat-load availability. Additionally, the rate of capital recovery of heat-recovery equipment differs substantially from production-related equipment as it is typically fixed by utility rates and current market values of fuels and cannot be as easily adjusted by manipulating product selling prices. The most appropriate type of heat-recovery equipment is determined based on technical feasibility, annual cost savings, and capital cost. It can be dangerous to only use the simple payback period. For example, industrial heat pump applications typically have longer simple payback periods (two to five years) than heat exchanger options although they usually provide better long-term solutions (DOE 2003b). Instead, proper discounted cash flow analysis should be used for accurate comparison of alternatives. Advancements in Heat Recovery Technology and Applications New heat recovery technology has been evolutionary and not revolutionary. However, improvements in efficiency and design of heat exchangers and heat pumps have led to new applications and improved paybacks for previous applications. Current heat recovery equipment can be constructed in special materials to withstand high temperatures, chemicals, and corrosion. For example, commonly used metallic radiation recuperators typically cannot handle inlet temperatures exceeding 2,000 oF but ceramic radiation recuperators can tolerate exhaust gas temperatures up to 2,800 oF. Additionally, condensing boiler economizers constructed in corrosion-resistant material can recover both sensible and latent energy from the exhaust gases. Recent advancements in heat pump technology to increase COP and lower capital costs include improvements in compressor and heat exchanger efficiencies. For example, the isentropic efficiency of single-stage centrifugal steam compressors used in mechanical vapor recompression (MVR) has increased from about 70% to above 80%, resulting in operating cost savings of about 10% (Global 2006a). Turbo-blower type compressors have also been developed for steam compressor applications. They operate at lower speed, allow for large vapor volumes over pressure ratios (up to 1.3), and have lower capital costs relative to centrifugal compressors. With efficiencies greater than 80%, they help improve the economics of MRV systems further. Selected Recent Applications of Heat Recovery Technology Miscellaneous applications (Trivedi, Kirtan K., Fouche, Ed and Parmenter, Kelly E. 2007). Global Energy Partners, in collaboration with EPRI, has conducted about 70 waste-heat recovery analysis for a wide range of manufacturing industries in North America, including pulp and paper; petroleum; petrochemicals; inorganic chemicals; general organic chemicals; fertilizers and © 2007 ACEEE Summer Study on Energy Efficiency in Industry 2-8

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