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transportability of heat streams. Hot liquid streams in process industries are frequently recovered, since they are easily transportable. Piping systems are easy to tap into and the energy can be easily transported via piping to the recovery equipment. In contrast, hot solid streams (e.g., ingots, castings, cement clinkers) can contain significant amounts of energy but their energy is not easily accessible or transportable to recovery equipment. As a result, waste energy recovery is not widely practiced with hot solid materials. 3.0 Waste Heat Recovery Options and Technologies Methods for waste heat recovery include transferring heat between gases and/or liquids (e.g., combustion air preheating and boiler feedwater preheating), transferring heat to the load entering furnaces (e.g., batch/cullet preheating in glass furnaces), generating mechanical and/or electrical power, or using waste heat with a heat pump for heating or cooling facilities. Sections 3.1 and 3.2 discuss technologies for heat exchangers and for load preheating systems, while Section 3.3 addresses challenges and opportunities specific to lowtemperature waste heat recovery. Section 3.4 discusses power generation options, and Section 3.5 contains summary tables comparing different recovery technologies. The terminology for heat recovery technologies frequently varies among different industries. Since this report addresses multiple industries, the terminology used below is the basis for all subsequent discussion of heat exchange technologies in different industries. 3.1 Heat Exchangers Heat exchangers are most commonly used to transfer heat from combustion exhaust gases to combustion air entering the furnace. Since preheated combustion air enters the furnace at a higher temperature, less energy must be supplied by the fuel. Typical technologies used for air preheating include recuperators, furnace regenerators, burner regenerators, rotary regenerators, and passive air preheaters. 3.1.1 Recuperator Recuperators recover exhaust gas waste heat in medium to hightemperature applications such as soaking or annealing ovens, melting furnaces, afterburners, gas incinerators, radianttube burners, and reheat furnaces. Recuperators can be based on radiation, convection, or combinations: • A simple radiation recuperator consists of two concentric lengths of ductwork, as shown in Figure 4a. Hot waste gases pass through the inner duct and heat transfer is primarily radiated to the wall and to the cold incoming air in the outer shell. The preheated shell air then travels to the furnace burners. • The convective or tubetype recuperator, Figure 5a (heat exchanger) passes the hot gases through relatively small diameter tubes contained in a larger shell. The incoming combustion air enters the shell and is baffled around the tubes, picking up heat from the waste gas. • Another alternative is the combined radiation/convection recuperator, shown in Figure 4b and 5b. The system includes a radiation section followed by a convection section in order to maximize heat transfer effectiveness. Recuperators are constructed out of either metallic or ceramic materials. Metallic recuperators are used in applications with temperatures below 2,000oF [1,093oC], while heat recovery at higher temperatures is better suited to ceramictube recuperators. These can operate with hotside temperatures as high as 2,800oF [1,538oC] and coldside temperatures of about 1,800°F [982oC].13 12 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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