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5.3.1 RD&D Needs for LowTemperature Waste Heat Recovery Developing Heat Exchangers for Low Temperatures A major challenge for lowtemperature heat recovery from exhaust gases is the condensation and corrosion caused by cooling exhaust gases below their dew point temperature. Condensation heat recovery requires significantly higher capital and operating costs, which usually are not worth the energy saving benefits. While condensing economizers are commercially available, capital costs can be as much as three times that of conventional boilers.151 Alternate technologies, such as transport membrane condensers are being developed and may have lower costs.152 Recovery at low temperatures becomes increasingly challenging with chemically laden gas streams. These waste heat sources will have greater limitations that prevent cooling flue gases to low temperatures. In order to enable expansion of lowtemperature heat recovery, RD&D might involve improving methods for cleaning exhaust streams, developing low cost advanced heat exchangers that can withstand corrosive environments, developing heat exchangers that can be easily cleaned, or perhaps modifying process technologies in order to prevent introduction of chemicals that would prevent heat exchange. Another challenge for heat exchangers when working with lowtemperature fluids is the large heat transfer area required, especially if heat is to be recovered from gaseous exhausts. Developments that increase heat transfer coefficients in heat recovery systems could partially address this issue. Some examples of commercially available technology for improving heat technology coefficients are ceramic inserts used in radiant heating tubes, dimpled or finned tubes and heat pipes. EndUse Technologies for Lowtemperature Heat A further challenge for lowtemperature waste heat recovery is the limitations on available enduses. Potential enduses for lowtemperature heat include lowtemperature process heating, domestic water heating, and space heating. Additionally, as discussed in Sections 3.33.4, heat pumps and low temperature power generation are options for recovery from lowtemperature heat sources. Heat pumps can be used to “upgrade” waste heat if a heat load is available at a temperature slightly higher than the waste heat temperature. Heat pump technology is welldeveloped, but improvements could be made that lower capital costs or improve heat pump performance (for example, innovative working fluids could be developed to increase heat pump efficiency). Lowtemperature power generation technologies are an emerging opportunity. Power cycles such as organic Rankin cycles and the recently developed Kalina cycle have been successfully installed in lowtemperature industrial applications. Longerterm technologies under investigation, such as piezoelectric generation, are not yet economical. Efforts can be made in further demonstrating emerging power cycles, improving these power cycles, and developing alternative generation systems. 5.4 Optimization of Systems Already Incorporating Waste Heat Recovery 5.4.1 Heat Losses from Units Already Including Waste Heat Recovery Many of the applications analyzed in this study already include waste heat recovery technologies, especially in large systems with relatively clean exhaust gases. For the processes analyzed, Table 22 and Figure 31 display estimated current industrial energy consumption and waste heat losses from units using heat recovery technologies and those not using heat recovery. Example units incorporating heat recovery include boilers, ethylene furnaces, cement preheater kilns, glass regenerative and recuperative furnaces, recuperative aluminum melting furnaces, etc. 56 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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