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Industrial Waste Heat Recovery: Potential

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Industrial Waste Heat Recovery: Potential ( industrial-waste-heat-recovery-potential )

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particulates, which can be considered relatively clean, and are discharged into the atmosphere from stacks. There is no simple method of recovering heat from these gases. It is likely that the heat can be used for power generation using low-temperature power generation systems; however, at this stage the economics do not look favorable due to the long payback time.  Clean boiler flue gases at low temperatures: These may be used for heating water in direct or indirect heat exchangers. Carbonic acid condensation could be a concern unless the water is used as “once-through water” or a slight increase in acidity does not affect the system. The economics of this may be marginal.  Energy used in the incinerator is relatively low: It is possible to use a recuperator or regenerator for heat recovery; however, the payback time could be long. Rolling Mill and Finishing Area Rolling and finishing typically include reheat furnaces, annealing furnaces, and continuous annealing lines. The furnaces use natural gas, COG, and BFG as mixed fuel. The slabs’ drop-out temperature is 2,150°F (1,180°C), and the furnaces include a recuperator to preheat combustion air. For older installations (pre-1980s), air temperature can be very low (less than 700°F or 370°C), while the exhaust gas temperature varies from 1,000°–1,250°F (540°-680°C), with a large percentage of O2 (sometime higher than 8%). Areas of waste heat include the following:  Exhaust gas from furnaces: The gases are relatively clean (free of particulates or condensable vapors); however, in some cases, they contain large amounts of excess air. Reducing O2 and recovering heat using better recuperators will be of great benefit.  Radiation heat from furnace openings: Radiation heat usually comes from the charge and discharge end as well as from other areas, including the roof and parts of the furnace shell or walls.  Heat from rolled steel shapes: The industry normally does not recover heat from rolled shapes, thus it may be beneficial to consider heat recovery. Steel – Mini Mill or EAF Mill The following are types of waste heat sources typically present at almost all EAF steel-making plants:  Waste heat in clean exhaust gases from reheat furnaces, tundish heaters, and ladle heaters: These gases are in the range of 1,000°F (540°C) from the heat furnace respirators to 1,800°F (980°C) from ladle and tundish heaters. These gases contain combustion elements of natural gas and do not contain any major contaminants. They are prime candidates for additional heat recovery as they contain as much as 35% of the total heat input for the heating systems. o Possible options for heat recovery include higher efficiency heat recovery system charge or load preheating, either recuperator or regenerative; load or charge preheating; steam and power generation; and the use of low-temperature power generation cycles, such as an organic Rankine cycle based system. There is very little need for heat recovery for hot water, hot air, or cooling systems. Industrial Waste Heat Recovery Page 14

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