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Aluminum – Recycling and Secondary Melting The following is a list of the types of waste heat sources typically found in secondary aluminum melting: Waste heat in clean exhaust gases from reverb furnaces, gas generators, and crucible heaters: These gases range from 1,450°F (790°C) in the crucible heaters to 2,000°F (1,090°C) in reverb furnaces, contain combustion products of natural gas, and do not contain any major contaminants. They are prime candidates for heat recovery for preheating combustion air. These gases contain as much as 60% of the total heat input for the heating systems. Possible options for heat recovery include combustion air preheating using recuperator or regenerative type units, or low-temperature power generating cycles such as an organic Rankine-cycle based system. There is very little use for hot water, hot air, or a cooling system, which could be used for heat recovery. Waste heat from rotary furnaces: These gases are relatively cold and contain a large amount of contaminants. The mass flow rate is cyclic and often unpredictable. There is no industry accepted method of recovering sensible heat from these gases. Development of a low-pressure drop filter or higher temperature fabric material for baghouses can help clean up the gases so they can be used for heat recovery. Waste heat from delacquering systems: These systems remove volatile materials from the UBCs and preheat them to about 900°F (480°C) before they are discharged from a rotary kiln. The preheated but partially cooled UBCs are charged in the reverb furnace. Delacquering systems use a gas generator that incinerates volatiles from the paint coating on UBCs. The exhaust gases from the unit are relatively clean and are discharged at about 650°F (340°C). There is no heat recovery from these gases. Waste heat from crucible heaters: These are relatively small units used to preheat crucibles before pouring hot aluminum metal from rotary furnaces or reverb furnaces. The burners are relatively small and fired in an uncontrolled fashion. The gases are discharged at about 1,450°F (790°C) and the heat is not recovered. Steel – Integrated Steel Mill This section discusses the following three areas of waste heat in an integrated steel plant and addresses primary and secondary sectors of the steel industry: Blast furnaces and the iron-making process, including power generation at the site Coke ovens and coke oven gas processing equipment Reheating and heat treating furnaces at a rolling and finishing area Blast Furnace, Iron Making, and Power Generation This area includes iron making in blast furnaces, power plants that include gas-fired boilers and steam turbine generators, and steel making using a Basic Oxygen Process (BOP) system. This section details areas in which waste heat is available and comments on its characteristics and use. Blast Furnaces (BF) A blast furnace uses a hot air blast with oxygen enrichment to increase production. In some plants, natural gas injection and coal injection have been used. The preheated blast air is used at 1,950°– 2,050°F (or 1,066°–1,122°C) and includes 5%–10% added oxygen. The waste heat discharged from the Industrial Waste Heat Recovery Page 11PDF Image | Industrial Waste Heat Recovery: Potential
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