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Waste Heat Source Hot clinker Exhaust gases from pre-heaters and other areas Heat Recovery Opportunities Recovery of sensible heat. Recovery of sensible heat. Barriers or Limitations – Currently Available Equipment No major technological barriers. The use of available waste heat within the plant presents a logistical barrier. No major technological barriers. The use of available waste heat within the plant presents a logistical barrier. Exhibit 9: Matrix of Waste Heat Sources, Recovery Opportunities and Barriers for the Cement Industry Hot surfaces - kiln shell Heat recovery in the form of electricity using TEG devices. Availability of materials and method of their use for the kiln walls to reduce surface temperature. There is no simple recovery of heat without affecting temperature profile within the kiln. Exhibit 10: Matrix of Waste Heat Sources, Recovery Opportunities and Barriers for the Food (Snack) Manufacturing Industry Waste Heat Source Exhaust gases from fryers. These gases contain moisture and oil vapors. Hot wash water (120°–180°F or 50°–82°C) from various sources. Waste material with organic content or heat value and moisture Heat Recovery Opportunities Recovery of sensible heat, use of heating value content of oil vapors and latent heat of moisture. Sensible heat of water Recovery and use of heating value content of the waste material. Barriers or Limitations – Currently Available Equipment Presence of oil vapors prevents use of conventional heat recovery (e.g., recuperates, heat wheels, condensing heat exchangers). Presence of particulates, economics of heat recovery, and lack of use of low-grade heat in the forms of warm water or air in the plant. Economic justification, availability of combustion equipment that can burn or process such waste economically. Clean exhaust gases from boilers, corn products dryers, oil heaters, and other sources Low-temperature (<500°F or 260°C) heat recovery from combustion products with moisture content of 20%–40%. No major technical barriers. Economics of heat recovery system installation and use of recovered heat within the plant are two major barriers. Electricity generation using heat from these sources using low-temperature systems (i.e. ORC) is uneconomical at the current state of technology. Exhibit 11: Matrix of Waste Heat Sources, Recovery Opportunities and Barriers for the Glass Industry Waste Heat Source Heat Recovery Opportunities Barriers or Limitations – Currently Available Equipment Melting furnace flue gases with regenerators Medium-temperature (<900°F or 480°C) heat recovery for power generation. The gases may contain some particulates but no condensable components. Availability of reliable and efficient heat exchangers, small size boilers and steam turbine power generation system that can be used for relatively small and low-temperature waste heat sources. Melting furnace flue gases with oxy- fuel systems Cleaning or filtering particulates from high-temperature (>1,600°F or 870°C) exhaust gases containing corrosive components. This will allow recovery of heat from exhaust gases at higher temperatures without pre-cooling them. Availability of reliable and efficient heat exchangers, small size boilers, and steam turbine power generation system that can be used for relatively small and low-temperature waste heat sources. All fuel-fired melting systems Using heat of low-temperature clean exhaust gases (<400°F or 204°C) discharged from ESPs or baghouses. Cost, reliability, and industrial installation demonstration of currently available low-temperature power generation systems (ORC and others). Melters and forehearth outer surfaces or casing High-temperature (>400°F or 204°C) furnace walls. Cost, reliability, and industrial installation demonstration of currently available low-temperature power generation systems (ORC and others). Annealing lehrs (temperature controlled kilns), tempering furnaces, or drying ovens Reducing air leakage from inlet- outlet sections or areas. The equipment design and operational components that require flexibility of operation. Availability of low-temperature heat recovery systems, cost of combustion system using preheated air. Industrial Waste Heat Recovery Page 28PDF Image | Industrial Waste Heat Recovery: Potential
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