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Example: Sulphuric acid plant The following is a typical example from a metallurgical sulphuric acid plant. Here there are often opportunities to recover waste heat from the acid plant absorption towers and reuse it for heating in mineral processing steps. Examples where the heat can be reused are copper electrolyte heating, spent acid and zinc sulphate solution heating in zinc plants, boiler feed water heating, etc. Before the technology change, the hot sulphuric acid from the absorption towers was cooled off in a shell-and-tube heat exchanger. Afterwards, the heat is transferred to a heat integration loop via a compact heat exchanger and released to an electrolyte heating bath. The result is 10 MW (34 MMBtu/h) of recovered energy. Results Increased heat recovery 10 MW 34 MMBtu/h Reduced cooling water temperature, fixed flow of 1,000 m3/h (4,400 gpm) Reduced CO2 emissions Assumptions SI American 8.5°C 15.3°F 18,000 metric tons/year Reduced cooling water flow, fixed ∆T = 10°C (18°F) 860 m3/h 3784 gpm • 60 W/m heat loss in pipeline • Boiler efficiency 90% (fuel savings case) • Turbine isentropic efficiency 80% (electricity generation case) • Total system operating and capital cost estimation based on real quotations • Demineralized water used in intermediate loop • Installation factors 1.5-2 for heat exchangers • Installation factor 3 for pipeline construction (insulated pipes) 39PDF Image | Waste heat recovery Optimizing
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