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H. Jouhara et al. Thermal Science and Engineering Progress 6 (2018) 268–289 condensate deposition. The system transfers heat from the exhaust gases to the cool water that is flowing through the pipes of the heat exchanger. This system provides the advantage of eliminating cross contamination of the flue gas and water and can be designed to work as a filter of a process [26]. 3.2. Transport membrane condenser Similar to direct contact condensation recovery systems, transport membrane condenser units produce hot water from water vapour from flue gas streams. As can be seen from Fig. 29, the system works by extracting and delivering the hot water back into the system feed water directly from the exhaust gas at a temperature above the dew point through a capillary condensation channel [146]. This way, unlike direct contact condensation recovery systems, the water is extracted through a membrane channel rather than directly from the flue gas and so the recovered water is not contaminated and does not require filtering. 4. Summary table The table below shows a summary of all the technologies in- vestigated in this paper including their temperature range, benefits and limitations: 5. Waste heat recovery opportunities in industry Different industrial processes consume different amounts of energy and produce different quantities and qualities of waste heat. To take advantage of the potential of industrial waste heat, it is therefore es- sential to look into and analyse the industrial processes used in large energy consuming industries and to investigate what suitable waste heat recovery methods can be applied to the systems of each sector. As mentioned before and indicated by McKenna and Norman [157], the largest amounts of industrial waste heat in the UK are mainly as- sociated with cement, ceramics, iron and steel, refineries, glassmaking, chemicals, paper and pulp, and food and drink industries. When con- sidering waste heat recovery options for industrial processes, it is im- portant to examine the source and the usefulness of the waste heat produced and discover which waste heat recovery method is the most suitable. In this paper, the iron and steel, ceramic and food industries were selected to investigate how optimising energy management through the use of waste heat recovery systems could be achieved in each sector. The reason for selecting the mentioned industries to conduct further investigations for the application of WHR is give an indication how and what WHR technologies can be applied to different industrial and production processes that demonstrate all waste heat temperature ranges (low-high). 5.1. Waste heat in iron and steel industry Iron and steel production is a resource and energy intensive process which involves extensive amounts of heat and raw material. Waste heat recovery in the iron and steel industry includes recovering heat dis- sipated from high-temperature sources such as furnaces used for sinter, coke, iron, and steel production, which is investigated to account for roughly 8% of the overall industrial energy consumption in the UK [4]. A common method of waste heat recovery in the iron and steel in- dustry is from clean streams of gases from production processes. For instance, Jouhara et al. [158] in an experiment demonstrated that for a heat source of 450 °C, the use of a Flat Heat Pipe (FHP) in the wire cooling line of a steel production facility can offer a recovery of heat up to 15.6 (kW). In this experiment, an innovative FHP model was con- structed at the dimensions of 1 m height × 1 m width and tested at the hottest point of the cooling zone of the production line. The model was charged with water at a flow rate of 0.38 kg/s and hot gases dispersing from the process impacted on a flat heat pipe panel which was inclined at an angle to the horizontal. In another study demonstrated by [159] and with the use of waste heat boiler, a waste heat recovery system was produced that can re- cover sensible heat from hot air emitted by the cooling process of sinter coolers located downstream of sinter machines. The system generated approximately 280 MW of power, increasing the overall efficiency of the plant by almost 6%. Heat recovery plant for contaminated and dirty exhaust gases from coke ovens, blast furnaces, oxygen furnaces and electric arc furnaces are also available, yet implemented less, due to the limitations and high capital costs of current methods [160]. For instance, Mandil [161] re- ports that the procedure for producing coke in coke ovens extracts gas with high quality waste heat from the exit of the coke oven and the (a) TMC Unit placed in a Duct (water passing through pipes). (b) TMC Unit placed in a Duct (flue gas passing though pipes). Fig. 29. Shows different transport membrane condenser units [156]. 280PDF Image | Waste Heat Recovery Technologies and Applications
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