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systems. Due to this variability, it is difficult to discuss waste heat recovery on a plant-by-plant, equipment, or process basis. However, a discussion of broad categories of waste heat sources and issues related to waste heat recovery in a “typical” petrochemical industry plant is possible. The following areas of waste heat are representative of major petrochemical operations: Exhaust gases from boilers, fired heating systems (i.e., crackers), and power generation (combustion turbine plus HRSG) equipment: In most cases, when natural gas is used as fuel, the gases are clean and the plants use currently available technologies for heat recovery. The waste heat discharged ranges from 200°–350°F (95°-180°C). The waste gas stream temperature could be higher for equipment using by-product fuels. Exhaust gases from thermal oxidizers (TO): TOs are often used for process heating equipment. The temperatures of exhaust gases from TOs range from 1,400°–1,800°F (760°-980°C) and may include chlorinated gases, or gases with other non-organic contaminants that are highly corrosive. Use of heat recovery equipment can be challenging. Higher temperatures and the presence of corrosive gases do not allow use of economically justifiable heat exchangers and, in many cases, it is necessary to quench the gases, resulting in loss of heat to scrubbing liquids. This presents additional problems with the need for additional water and, in some cases, cooling capacity. In generic terms, the issue is heat recovery from high-temperature gases containing corrosive components. Use of hydrogen from chlorine process: A by-product of hydrogen, RCL, can be a very good source of fuel; however, its use presents problems. Many plants face problems in recovering or using this by-product since RCL turns into HCL, which limits burning of this valuable by-product in power plants. Proper treatment to remove chlorinated components would increase use of this valuable fuel in power plants. Use of heat from exothermic processes in reactors: It may be possible to produce steam at high pressures (600–1,500 psig) for power generation. Quenching of some products produces hot water from which heat can be recovered. No simple method of recovering this heat is available at this time. Logistics of collecting stack gases and using them to heat liquids or gases: In most plants, there are multiple stacks and a collection of gases that present major hurdles. In addition to this use of heat exchangers, it is difficult to retrofit such units due to limits on available space. Compacting footprints will definitely encourage increased use of stack-gas heat recovery. Use of micro- channel heat exchangers has been considered; however, their availability and history of use in industrial installations is almost non-existent. Heat from gases containing water vapors discharged from evaporators and other units: These gases contain a large percentage of their heat in vapors and need cooling below condensation temperature to recover latent heat. In many cases, available water temperature, size of the units, and quality of vapors (contaminations) limit use of convention heat exchangers. Development of condensing heat exchangers in smaller footprint sizes would be useful in recovering a large percentage of heat wasted in these types of streams. These heat exchangers would result in water conservation. Some companies have considered use of permeable membranes and other similar vapor heat recovery systems without much success. Heat from hydrocarbon processing units: In the hydrocarbon processing units, heat is wasted in massive volumes of low-pressure steam. Recovering heat from this source is a challenge for the plant. In many cases, this is limited by availability and cost of pumping cooling water as well as Industrial Waste Heat Recovery Page 16PDF Image | Industrial Waste Heat Recovery: Potential
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