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3.3 LowTemperature Energy Recovery Options and Technologies While economics often limit the feasibility of lowtemperature waste heat recovery, there are various applications where lowgrade waste heat has been costeffectively recovered for use in industrial facilities. The large quantities of waste heat available in the range of 100400°F [38200°C] and the inherent challenges to its recovery and use warrant a separate and indepth investigation of low temperature waste heat recovery. Much industrial waste heat is in the lowtemperature range. For example, combustion systems such as boilers frequently use recovery technologies that exhaust gases at around 300350°F [150°180°C], accounting for at least 460 TBtu of waste heat per year (see Section 4 Evaluating Selected Applications). Meanwhile, large quantities of waste heat can be found in industrial cooling water and cooling air; for example cooling of air compressors alone accounts for about 18 TBtu of waste heat per year. One integrated steel mill in Japan successfully installed a power generation plant with a 3.5 MW capacity using cooling water at only 208°F [98°C].17 In the case of combustion exhaust gases, substantial heat can be recovered if water vapor contained in the gases is cooled to lower temperatures. Minimum temperature limits around 250300°F [120150°C] are frequently employed in order to prevent water in the exhaust gases from condensing and depositing corrosive substances on the heat exchanger surface. However, cooling the flue gas further could significantly increase heat recovery by allowing the latent heat of vaporization to be recovered. A pound of water requires 1,000 Btu of energy to evaporate. Conversely, if a pound of water vapor condenses, it transfers 1,000 Btu to its environment. This latent heat comprises a significant portion of the energy contained in exhaust gases. Technologies that can minimize chemical attack while cooling exhaust gases below the condensation point can achieve significant increases in energy efficiency via recovering the latent heat of evaporation. Figure 13 below displays the energy recovered per pound of fuel with different stack exit temperatures. If gases are cooled from 300°F [150°C] to 140°F [60°C], then the facility can obtain a 3% efficiency increase. Cooling gases further to 100°F [38oC] captures a portion of the latent heat and can provide an 11% efficiency increase. Figure 13 Heat Recovery Curve for Natural GasFired Boiler (Source: Goldstick, 1986) 18 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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