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Economiesofscale dictate the economic viability of many heat recovery systems. This can be due to lack of capital available in smaller operations, as well as relatively longer payback periods involved for heat recovery installations. A good example of the relationship between furnace size and recovery practices is in the glass melting industry. As shown in Figure 32 and Table 23, typical furnace capacities vary in different segments of the glass industry. Flat glass and container glass melting is performed in large furnaces, while average capacities for pressed/blown glass, insulation fiber glass, and textile fiber glass are much smaller. One can note that smaller capacity furnaces typically have a higher percentage of waste heat losses. 70% 60% 50% 40% 30% 20% 10% 0% Typical Furnace Size and Waste Heat Loss in Different Segments of Glass Industry Pressed/Blown Textile Fiber Insulation Fiber Container Flat Glass 0 100 200 300 400 500 600 Typical Size (tons/day) Figure 32 Relationship between Typical Furnace Size and Average Waste Heat Losses in Different Segments of the Glass Industry (Note: Table 21) Table 23 Typical Furnace Capacities and Waste Heat Losses in Different Segments of Glass Industry Furnace Capacity Range a Typical Furnace Capacity a Natural Gas Consumption TBtu/yr Waste Heat TBtu/yr % Nat. Gas Input Lost to Waste Heat Glass Industry Segment Flat Glass Container Glass Pressed/ Blown Glass Insulation Fiber Glass Textile Fiber Glass a. Source: Energetics, Energy and Environmental Profile of the U.S Glass Industry, 2002, p. 54 Another key challenge to heat recovery is exhaust gas chemical composition. Heat recovery is more common with clean gaseous exhaust streams, including exhausts from boilers, ethylene furnaces, and hot blast stoves. Heat recovery is less common when processrelated chemicals in exhaust streams increase the complexity of waste heat recovery. Examples include dust in steel electric arc furnaces, chlorides and fluorides in secondary aluminum melting, sulfates from glass melting, and tars in coke oven gas. In the case of coke oven gas, no current facilities in the United States use waste heat recovery. In other cases such as glass melting furnaces, steel electric arc furnaces, and secondary aluminum furnaces, some facilities are currently using waste heat recovery techniques, but only to a limited extent. 3001000 550+ 50550 250 1300 75 20300 100 41.10 11.82 29% 45.49 13.65 30% 16.82 9.63 57% 3.24 1.73 53% 100150 100150 11.05 6.14 56% 59 Percent Waste Heat LossPDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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