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3.1.2 Regenerator 3.1.2.1 Furnace Regenerator Regenerative furnaces consist of two brick “checkerwork” chambers through which hot and cold airflow alternately (Figure 6). As combustion exhausts pass through one chamber, the bricks absorb heat from the combustion gas and increase in temperature. The flow of air is then adjusted so that the incoming combustion air passes through the hot checkerwork, which transfers heat to the combustion air entering the furnace. Two chambers are used so that while one is absorbing heat from the exhaust gases, the other is transferring heat to the combustion air. The direction of airflow is altered about every 20 minutes. Regenerators are most frequently used with glass furnaces and coke ovens, and were historically used with steel openhearth furnaces, before these furnaces were replaced by more efficient designs. They are also used to preheat the hot blast provided to blast stoves used in ironmaking; however, regenerators in blast stoves are not a heat recovery application, but simply the means by which heat released from gas combustion is transferred to the hot blast air (see Section 4.3.1.2 Blast Furnace). Regenerator systems are specially suited for hightemperature applications with dirty exhausts. One major disadvantage is the large size and capital costs, which are significantly greater than costs of recuperators.14 Burner in use Fuel Burner withdrawn To Stack Air (a) (b) Figure 6 (a) Regenerative Furnace Diagram, (b) Checkerwork in Glass Regenerative Furnace (Source: GS Energy & Environment, 2007) 3.1.2.2 Rotary Regenerator/Heat Wheel Rotary regenerators operate similar to fixed regenerators in that heat transfer is facilitated by storing heat in a porous media, and by alternating the flow of hot and cold gases through the regenerator. Rotary regenerators, sometimes referred to as air preheaters and heat wheels, use a rotating porous disc placed across two parallel ducts, one containing the hot waste gas, the other containing cold gas (Figure 7). The disc, composed of a high heat capacity material, rotates between the two ducts and transfers heat from the hot gas duct to the cold gas duct. Heat wheels are generally restricted to low and mediumtemperature applications due to the thermal stress created by high temperatures. Large temperature differences between the two ducts can lead to differential expansion and large deformations, compromising the integrity of ductwheel air seals. In some cases, ceramic wheels can be used for highertemperature applications. Another challenge with heat wheels is preventing cross contamination between the two gas streams, as contaminants can be transported in the wheel’s porous material. 14 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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