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challenging. It is possible that a plant may consider using direct contact heat exchangers (condensing units) for heating water for process use or wash water if sufficiently large holding capacity is available. As far as the technology of heat recovery from such gases is concerned, it could be considered mature technology with several vendors offering heat exchangers. The primary issues include the economics, logistics, and scheduling of the use of recovered waste heat in the plant. R&D in this area should be considered a low priority. Waste heat in the form of exhaust gases with high moisture content and oil vapors, such as exhaust gases from fryers: These gases are at 350°F (180°C) and require “pretreatment” to remove oil vapors before heat recovery. There is no simple method of recovering this heat due to its lower temperature and the presence of condensable oil vapors—even after using filters or demisters that remove large amounts of, but not all, oil vapors from the gases. Cooling of these gases during a heat recovery process, such as in low-temperature power generation systems (if economically justifiable), could result in condensation of the residual oil vapors, resulting in heat transfer issues in conventional heat exchanger equipment used for such systems. Waste heat in heated water used as wash water: This heat is at a very low temperature (usually less than 100°F or 37°C) and can be used for preheating make-up water during colder months. Applicability of this option depends on the geographic location of the plant and can be an attractive option for plants located in colder weather areas, such as the northern United States. Low-temperature waste heat: Many progressive plants are considering several options for low- temperature heat recovery systems such as organic Rankine cycle systems (i.e., UTC, Ormat). However, there are limiting issues such as the low temperature of the heat source (as previously discussed), the requirement of low-temperature heat sink in the form of water used for the condenser section of these systems, and low energy conversion (heat to electric power) efficiency levels that severely limit economic justification for use of such systems. At least one company is considering use of CO2-based power conversion devices that allow use of lower temperature (<200°F or 94°C) heat sources. Cement – Dry Process and Shaft Furnaces Typical sources of waste heat for both old and small-sized shaft furnace types of units and plants that use the dry process are as follows: Clinker cooling air from cooling bed: The air temperature varies from 350°–900°F (180°-480°C). Waste heat recovery technologies used are preheating air from coal- and fuel-fired boilers to raise steam for power generation and for other auxiliary heating. No special R&D is required for heat recovery. Exhaust gases from the system, usually from the preheaters: These gases contain a high percentage of CO2 generated from the calcining reaction and products of combustion from fuels used in the kiln and precalciner. The gas temperature can vary from 300°–500°F (150°-260°C). In most cases, the exhaust gases are mixed with clinker cooling air and the heat is recovered in boilers or other heat recovery units. Hot shell or surfaces of kilns and precalciner: The surface temperature can vary from 500°–800°F (260°-430°C). There is no practical way to recover this heat yet. The best solution is to redesign the insulation-refractory system to reduce the kiln shell temperature. Industrial Waste Heat Recovery Page 18PDF Image | Industrial Waste Heat Recovery: Potential
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