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Waste heat from gases discharged from EAF: These gases are hot and contain large amounts of contaminants, and the mass flow rate is cyclic and often unpredictable. Currently, there is no industry-accepted method of recovering chemical and sensible heat from these gases. Waste heat from hot surfaces or reduction of heat from the walls of ladle and tundish heaters. Glass – Fiberglass Manufacturing The following discusses waste heat discharged from the major energy use systems in the fiberglass industry; however, most energy-use systems are very similar in other glass plants, particularly as they relate to waste-heat discharge and their characteristics: Glass melters: The melters can use natural-gas-fired burners with preheated air or oxy-fuel burners or electricity as a source of heat used in glass melting. The fuel-fired systems may use electric boost to supplement heat supplied from gas-fired burners. The melters include channels that are gas-fired and discharge large amounts of hot gases vented directly into the building. Energy consumption of the melters varies depending on the type of heating system used. o Sources of waste heat include exhaust gases from the furnace and channels. These gases are at very high temperatures (in excess of 2,500°F or 1,370°C) and contain a large amount of contaminants, such as inorganic particles and vapors of elements that condense in a certain temperature range. The nature of the elements depends on the type of glass and operating practices. These gases are quenched by blending a large amount of air. For some glass plants, a recuperator or regenerative system is used. The gases from the system can be from 450°–900°F (230°-480°C). The gases discharged from the baghouses used for collecting the particulates can be as high as 450°F (230°C). Fiberizing process: The fiberizing process uses a large quantity of natural gas for maintaining the required temperature conditions. The heating system can be very complex and has to be “tuned” to give the desired quality specifications for the fibers. The plants are continually looking at methods to reduce energy use in the system. The waste heat is in the form of hot gases; however, due to blending with lots of air or steam, the temperature is low (sometimes less than 500°F or 260°C) and collection of the gases is very difficult. Curing ovens: The curing ovens use natural-gas-fired burners with recirculation fans. The oven’s operating temperature varies with the type of process and product going through, ranging from 450°–550°F (230°-290°C). It is likely that the exhaust gas volume is much higher than the volume of combustion products from the burners due to large air leaks into the ovens. The exhaust gases are usually incinerated to remove the organic contents of the exhaust gases. In many cases, the incinerators use regenerative heat recovery systems, and the exhaust gases are discharged at or below 375°F (190°C). The waste heat source is low-temperature clean gases. Space heating: Space heating is a major area of energy use for plants in cold weather areas. In such areas, space heating of a building can require 25% or higher of the total plant energy use during the colder months. This heat is supplied by placing gas-fired unit heaters at several locations within the plant, particularly in the finishing, packaging, and shipping areas where there is no heat available from the furnaces and the curing oven. Chemicals and Petroleum Refining – Major Operations Chemical industry companies manufacture a wide variety of products from a number of different raw materials, mostly hydrocarbons, and use a large amount of fuel to supply heat to process heating Industrial Waste Heat Recovery Page 15PDF Image | Industrial Waste Heat Recovery: Potential
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