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Coatings – Vinyl Coating Mill The following are representative of typical waste heat sources for medium-sized coating plants producing flooring and other products: Ovens: Ovens are used to heat vinyl or other material coated with different substances and to cure the material. The ovens have several (typically 10–14) zones, each with its own burners, recirculating fans, and discharge ducts. The ducts from several zones are combined into a single common duct that is connected to one or more regenerative thermal oxidizers. During the heating process, volatile organic compounds (VOCs) are generated that get mixed with make-up air or air leaking into the ovens. The material is heated to 300°–400°F (150°-200°C) and then cooled before it is discharged. It is necessary to maintain a minimum amount of air flow into the oven to meet safety regulations. The regulations require use of enough air to maintain a minimum of 25% LEL value for the VOCs inside the oven. The ovens use infrared (IR) zones as supplemental heat supply. The waste heat is in the form of chemical heat of VOCs and sensible heat of air. These gases are required to be incinerated to remove air pollutants; hence, they are not considered a direct waste heat source. Dryers: The production process requires printing of the product using non-solvent-based ink. Two dryers are used to dry ink. The dryers, which are on the roof of the plant, use recirculating air flow that is heated by air heaters also located on the roof. The air heaters use ratio-type burners and recirculating fans. A certain amount of exhaust air is discharged from a single duct. The air flow is required to maintain proper humidity that allows an efficient drying process for the air being recirculated. The exhaust air at 300°F (150°C) and higher contains clean heat that represents a large percentage (in excess of 50%) of the total heat input to the dryer. Regenerative thermal oxidizers (RTOs): These plants use RTOs to destroy VOCs generated in the ovens. There could be one or more RTOs for each oven. The RTOs are designed to recover heat from the incineration or combustion chamber section of the system to preheat incoming exhaust air from the ovens. The RTOs discharge clean exhaust air at about 350°–400°F (180°- 200°C). They seem to be very efficient in recovering heat from the exhaust gases. It is necessary to operate the RTOs at a temperature higher than 1,500°F (816°C) to meet the local air emission regulations. These units are tested regularly to assure their regulatory compliance. Waste heat from these units is discharged at about 350°–400°F (180°-200°C) and can be recovered to supply heat in the ovens or to provide hot water or make-up air for the plant. Steam boilers: The boilers are used to supply steam to the processes and for plant space heating during the colder winter months where it is required. Typically, the boilers discharge flue gases at about 500°F (260°C) and they do not have any type of heat recovery for the exhaust gases. The boiler drum blow-down is continuous and manually controlled. No heat recovery system exists for the blow-down water. The amount of boiler blow-down water is unknown. The steam is distributed over fairly long distances through a network of steam piping and condensate returns to the boiler house. Waste heat sources are exhaust gases at 500°F (260°C) and boiler blow-down water at the operating pressure (150 psig and higher). The waste heat can be recovered using commercially available heat recovery systems. Oil heater: Some of the ovens use a hot oil recirculation system to supply hot air to the ovens. The oil heater uses natural-gas-fired burners to produce hot gases that are used to heat recirculating oil. This unit discharges exhaust gases at relatively low temperatures (350°F (180°C) or lower). The waste heat in exhaust gases can be recovered by using commercially available equipment. Industrial Waste Heat Recovery Page 19PDF Image | Industrial Waste Heat Recovery: Potential
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