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Key conclusions are as follows: The economic justification of heat recovery systems depends on the temperature and quality or cleanliness of the waste streams; the magnitude of waste heat; the system’s cost-benefit ratio; and, most importantly, the cost of energy—particularly fuels, natural gas, and coal. A large number of technologies and systems are available to recover heat from medium (600°– 1,200°F or 316° - 650°C) and high-temperature (>1,200°F or 650°C) clean gases discharged from industrial processes. In most cases, there is an upper temperature limit (>1,600°F or 870°C) that restricts use of the available equipment. Several systems are available to recover heat from lower temperature clean gases and liquids; however, current energy prices prevent their wide-scale use. Next to the cost of energy, the equipment performance of waste heat recovery technologies is the most important issue preventing use of waste heat systems in all temperature ranges. For example, a large amount of waste heat is available in high-temperature processes; however, the waste heat streams contain many contaminants that severely limit use of existing waste heat recovery systems. On the other hand, thermodynamic limitations and the lack of economically justifiable, efficient energy conversion systems prevent wide-scale use of heat recovery from low- temperature waste heat streams. In many cases, the available technologies and hardware can economically recover large amounts of heat in the form of hot air (gas), liquid (water), or steam. However, in most cases there is very little use of such energy sources in the plant. The best form of energy conversion seems to be electricity that is easily transportable or can be exported to the utility company. Currently available technologies and systems need several improvements before they are accepted by the industry. Additional R&D efforts in this area could offer large returns. Addressing a number of technical issues and pursuing R&D efforts could allow further wide-scale use of waste heat recovery from high-temperature streams. Many technical issues and R&D efforts are related to materials and are designed to extend equipment life, reduce maintenance or cleaning time intervals, and provide consistent and reliable performance over an acceptable lifetime (usually several years). Specifically for low-temperature waste heat streams, cost, system size limitations, and the lack of use of low-grade heat within the plant are major barriers to waste heat recovery. The very low temperature of the heat source places severe limitations on heat transfer rates and requires large surface areas, resulting in large footprints and unjustifiable economics. Development of micro- size heat exchangers, designs that offer large area-to-volume ratios (smaller footprint), and materials that can withstand the corrosive properties of low-temperature streams (condensed liquids from flue gases) are required for wide-scale adoption of low-temperature heat recovery systems. Usage of recovered waste heat within the plant remains a substantial hurdle and presents a cost justification issue for plant management. viiiPDF Image | Industrial Waste Heat Recovery: Potential
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