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Limitations of Currently Available Technologies Exhibits 16 and 17 depict limitations and barriers of currently available waste heat recovery technologies for ultra-high, high, and medium temperature ranges. Exhibit 16: Limitations of Currently Available Waste Heat Recovery Technologies, High and Ultra High Temperature Ranges Equipment Limitations and Barriers Metallic recuperators Upper temperature limit of 1,600° to 1,800°F (or 870° to 980°C) Economically justifiable heat recovery efficiency – 40%–60% High maintenance for use with gases containing particulates, condensable vapors, or combustible material Life expectancy in applications where the mass flow and temperature of the fluids vary or are cyclic Fouling and corrosion of heat transfer surfaces In some cases, difficulty in maintaining or cleaning the heat transfer surfaces Ceramic recuperators Life expectancy due to thermal cycling and possibility of leaks from high-pressure side Initial cost Relatively high maintenance Size limitations – difficult to build large size units Recuperative burners Lower heat recovery efficiency (usually less than 30%) Temperature limitation – exhaust gas temperature less than 1,600°F (870°C) Limited size availability (usually for burners with less than 1 MM Btu/hr) Cannot be applied to processes where exhaust gases contain particles and condensable vapors Stationary regenerators Large footprint Declining performance over the lifetime Plugging of exhaust gas passages when the gases contain particulates Chemical reaction of certain exhaust gas constituents with the heat transfer surfaces Possibility of leakage through dampers and moving parts Cost can be justified only for high-temperature (>2,000°F or 1,100°C) exhaust gases and larger size (>50 MM Btu/hr firing rate) Rotary regenerators Seals between the high-pressure and low-pressure gases (air) Plugging of exhaust gas passages when the gases contain particulates High pressure drop compared to recuperators Maintenance and operation reliability for rotary mechanism Regenerative burners Large footprint for many applications Complicated controls with dampers that cannot be completely sealed Difficult pressure control for the furnace Cost competiveness Plugging of the bed when the gases contain particulates. Require frequent cleaning of the media and the bed. Heat recovery steam generators - boilers Can be used for large size systems (usually higher than 25 MM Btu/hr) Can be used only for clean, particulate free, exhaust gases Need to identify use of steam in the plant Initial cost is very high compared to other options such as recuperators Industrial Waste Heat Recovery Page 33PDF Image | Industrial Waste Heat Recovery: Potential
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