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Thermal Energy Equipment: Waste Heat Recovery 2.1.1 Metallic radiation recuperator The simplest configuration for a recuperator is the metallic radiation recuperator, which consists of two concentric lengths of metal tubing as shown in Figure 2. The inner tube carries the hot exhaust gases while the external annulus carries the combustion air from the atmosphere to the air inlets of the furnace burners. The hot gases are cooled by the incoming combustion air, which now carries additional energy into the combustion chamber. This is the energy, which does not have to be supplied by the fuel; consequently, less fuel is burned for a given furnace loading. The saving in fuel also means a decrease in combustion air and therefore, stack losses are decreased not only by lowering the stack gas temperatures but also by discharging smaller quantities of exhaust gas. The radiation recuperator gets its name from the fact that a substantial portion of the heat transfer from the hot gases to the surface of the inner tube takes place by radiative heat transfer. The cold air in the annuals, however, is almost transparent to infrared radiation so that only convection heat transfer takes place to the incoming air. As shown in the diagram, the two gas flows are usually parallel, although the configuration would be simpler and the heat transfer would be more efficient if the flows were opposed in direction (or counterflow). The reason for the use of parallel flow is that recuperators frequently serve the additional function of cooling the duct carrying away the exhaust gases and consequently extending its service life. Figure 2. Metallic Radiation Recuperator (Hardtech Group) 2.1.2 Convective recuperator A second common configuration for recuperators is called the tube type or convective recuperator. As seen in the figure below, the hot gases are carried through a number of parallel small diameter tubes, while the incoming air to be heated enters a shell surrounding the tubes and passes over the hot tubes one or more times in the direction normal to their axes. If the tubes are baffled to allow the gas to pass over them twice, the heat exchanger is termed a two-pass recuperator; if two baffles are used, a three-pass recuperator, etc. Although baffling increases both the cost of Figure 3. Convective Recuperator (Reay, D.A., 1996) Energy Efficiency Guide for Industry in Asia –www.energyefficiencyasia.org ©UNEP 2PDF Image | Thermal Energy Equipment Waste Heat Recovery
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