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H. Jouhara et al. Thermal Science and Engineering Progress 6 (2018) 268–289 Nomenclature Symbols HRSG Heat Recovery Steam Generator IC Internal Combustion ORC Organic Rankine Cycle RCA Spinning Disk Atomiser SDA Rotating Cup Atomiser WHR Waste Heat Recovery RAC run around coil Subscripts and superscripts CO carbon monoxide CO2 carbon dioxide CP Critical Pressure H2 Molecular Hydrogen Fe pig iron FeO iron oxide Tb Average Temperature Tc Temperature Cold ΔT Temperature Difference Cp specific heat (J/kg.K) h specific enthalpy (J/kg) Q heat content (J) q heat (J) s specific entropy T temperature (K) V flow rate (m3/s) w work (J) ρ density (kg/m3) Acronyms BOF Basic Oxygen Furnace CHP Combined Heat and Power CRC Clausius-Rankine Cycle (kJ/kg.K) energy efficiency through waste heat recovery models can help UK businesses to reduce the operating costs of their businesses, improve the energy efficiency of their sites and reduce the UK’s industrial CO2 emissions. 2. Waste heat recovery systems Waste heat recovery methods include capturing and transferring the waste heat from a process with a gas or liquid back to the system as an extra energy source [5]. The energy source can be used to create ad- ditional heat or to generate electrical and mechanical power [6]. Waste heat can be rejected at any temperature; conventionally, the higher the temperature, the higher the quality of the waste heat and the easier optimisation of the waste heat recovery process. It is therefore important to discover the maximum amount of recoverable heat of the highest potential from a process and to ensure the achievement of the maximum efficiency from a waste heat recovery system [7]. The quantity or the amount of available waste heat can be calcu- lated using the equation shown below. Q=V×ρ×CP ×ΔT (1) where, Q (J) is the heat content, V is the flowrate of the substance (m3/ s), ρ is density of the flue gas (kg/m3), Cp is the specific heat of the substance (J/kg.K) and ΔT is the difference in substance temperature (K) between the final highest temperature in the outlet (Tout) and the initial temperature in the inlet (Tin) of system. Depending on the type and source of waste heat and in order to justify which waste heat recovery system can be used, it is essential to investigate the amount and grade of heat recoverable from the process. Fig. 1. Energy consumption in the UK manufacturing industry [3]. 269 There are many different heat recovery technologies available which are used for capturing and recovering the waste heat and they mainly consist of energy recovery heat exchangers in the form of a waste heat recovery unit. These units mainly comprise common waste heat recovery systems such as air preheaters including recuperators, regenerators, including furnace regenerators and rotary regenerators or heat wheels and run around coil, regenerative and recuperative bur- ners, heat pipe heat exchangers, plate heat exchangers, economisers, waste heat boilers and direct electrical conversion devices. These units all work by the same principle to capture, recover and exchange heat with a potential energy content in a process. 2.1. Regenerative and recuperative burners Regenerative and recuperative burners optimise energy efficiency by incorporating heat exchanger surfaces to capture and use the waste heat from the hot flue gas from the combustion process [8]. Typically, regenerative devices consist of two burners with separate control valves, which are connected to the furnace and alternately heat the combustion air entering the furnace. The system works by guiding the exhaust gases from the furnace into a case which contains refractory material such as aluminium oxide [9]. The exhaust gas heats up the aluminium oxide media and the heat energy from the exhaust is re- covered and stored. When the media is fully heated, the direction of the flue gas is reversed, with the stored heat being transferred to the inlet air entering the burner and the burner with hot media starts firing. Combustion air from the hot media then heats up the cooler media and the process starts again. Through this technique, the regenerative burner can save the fuel needed to heat the air and this improves the efficiency of combustion [10] (see Fig. 2). Burners that incorporate recuperative systems are also used com- mercially. A recuperative burner has heat exchanger surfaces as part of the burner design, which capture energy from the heated gas that passes through the body of the burner [12]. The burner uses the energy of waste gas from the exhaust to preheat the combustion air before it gets mixed with the fuel. The burners consist of an internal heat ex- changer with various features such as grooves, counter current flow and fins, which are used to establish thermal contact between the waste exhaust gases and the combustion air coming from the supply pipe [13]. The design works by collecting the both the exhaust gas and waste heat from the body of the burner nozzle, and using them both to transfer heat into the combustion air. This air preheating results in an improved efficiency of combustion and thus more heat from the nozzle. It should be noted that the burner and the nozzle are inserted intoPDF Image | Waste Heat Recovery Technologies and Applications
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