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3.1.6 Waste Heat Boilers Waste heat boilers, such as the twopass boiler shown in Figure 11, are water tube boilers that use medium to high temperature exhaust gases to generate steam. Waste heat boilers are available in a variety of capacities, allowing for gas intakes from 1000 to 1 million ft3/min. In cases where the waste heat is not sufficient for producing desired levels of steam, auxiliary burners or an afterburner can be added to attain higher steam output. The steam can be used for process heating or for power generation. Generation of superheated steam will require addition of an external superheater to the system. 3.2 Load Preheating Load preheating refers to any efforts to use waste heat leaving a system to preheat the load entering the system. The most common example is boiler feedwater preheating, where an economizer transfers heat from hot combustion exhaust gases to the water entering the boiler (Section 3.1.4). Other applications utilize direct heat transfer between combustion exhaust gases and solid materials entering the furnace. For example, in the aluminum metal casting industry, stack melters can replace reverberatory furnaces to reduce energy consumption. With stack melters, ingots and scrap are charged through the top of the furnace and preheated by exhaust gases leaving the furnace. Figure 12 shows a stack melter at a die casting facility that has successfully reduced energy consumption to about 47% below conventional furnaces.16 While boiler feedwater preheating is a standard practice, load preheating of material prior to melting in directfired systems is not as widely used. This is due to a variety of factors, including difficulties in controlling product quality, issues associated with environmental emissions, and the increased complexity and cost of building advanced furnace loading/heat recovery systems. Nevertheless, heat recovery via load preheating has received increased attention over the last 10 years. The available technologies and barriers for different load preheating furnaces will vary substantially depending on the type of furnace and load in question. These considerations are discussed in more detail in Section 4, which describes processspecific constraints on heat recovery equipment. Figure 11 Waste Heat Boiler Figure 12 Stack Melter in a Die Casting Facility 17 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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