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Heat pumps for an industrial building (Fouche, Ed and Heck, Greg 2006). Southern Company is currently evaluating a dehumidification system for an industrial building. The system consists of heat pumps and desiccant wheel that pre-cools the incoming air. Heat from the condenser coils provides regeneration heat to the desiccant wheel. This technology is not yet commercialized. Heat pump/thermal storage for metal producer (Tri-State 2000a). Thermal storage can be used to transfer electric consumption off-peak. In the original system, the return cooling water was sent directly to a cooling tower and steam boilers handled the 5 million-Btu/hr heating need. The steam system was converted to a 150 °F hot water loop and a heat pump was used to reclaim waste heat from the cooling water. A 12,000-gallon storage tank enabled the heat pump to be turned off during peak electric demand hours. As a result, the 341-kW electric heat pump load does not contribute any additional peak demand and it can operate at a COP of 4.3. Steam recompression/open-cycle heat pump (Tri-State 2000b). A manufacturing plant had 50,000 lbs/hr excess of 40 psig steam while at the same time it required 300 psig steam. To address the plant’s steam needs, a steam compressor open-cycle heat pump was evaluated. A two-stage rotary screw compressor or a three-stage centrifugal compressor unit was proposed at an installed cost of $1,250,000. At an electric rate of $0.05/kWh and an annual operation of 8,000 hours, a simple payback of 2 years could be obtained. Flue gas heat recovery (Tri-State 2000c). Economizers and/or air preheaters are the most commonly used heat exchangers for flue gases. Economizers are usually an appropriate retrofit alternative if a boiler operates at significant loads all year long. For example, a boiler that operates at 150 psig saturated steam and generates 20,000 lbs/hr can typically save 2.4 MMBtu/hr if an economizer recovers waste heat from the flue gas. At a fuel cost of $4 per million Btu, this would save approximately $52,000 a year. Thermal oxidizer heat recovery boiler (DOE 2003c). A 3M Hutchinson plant evaluated two heat recovery applications: an oil-to-air heat exchanger to preheat supply air and makeup air, and a heat recovery boiler for low-pressure steam production. The payback period of the heat recovery boiler was much shorter than for the heat exchanger (1.2 years vs. 8.1 years). The use of a reheat boiler also mitigates the heat recovery limitations of an oil-to-air heat recovery system, as the annual energy reduction of such system is limited to the load of the specific air- handling units. Additionally, heat recovered from the thermal oxidizers for the production of low-pressure steam also can serve multiple loads throughout the plant. Annual steam production from the waste heat recovered is estimated to provide total energy savings of $772,000/year. The heat recovery boiler had a 1.2-year payback. Heat pumps in a waste burning power plant (IEA HPC 2004a). In 2000, Umeå Energi Ltd. built a power plant combined with a municipal/ industrial wood waste burning facility. The plant uses a heat recovery system with an integrated 14 MW compression heat pump that recovers waste condensing heat in the flue gas and transfers this waste heat into the district heating system. The plant also separates ammonia slip produced as a result of thermal NOx-reduction. Ammonia is recovered and recirculated to the boiler for reuse. © 2007 ACEEE Summer Study on Energy Efficiency in Industry 2-10PDF Image | Industrial Waste Heat Recovery Benefits and Recent Advancements in Technology and Applications
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