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Control system for ovens to regulate the amount of make-up air used. This will require development of a system that controls the amount of make-up air, and hence the amount of heat wasted from the oven. Opportunities for Aluminum Recycling Operations Cleaning of hot gases from rotary furnaces to allow heat recovery from exhaust gases. A heat recovery system for hot (>1,800°F or 980°C) exhaust gases containing materials such as flux material and aluminum oxide particles. Secondary heat recovery from gases discharged from recuperators used for combustion air preheating. The gases could be in the temperature range of 400°–800°F (200°–430°C). Opportunities for the Cement Industry Heat recovery from hot surfaces or kiln shell surfaces. Cleaning (particulate removal) of heated clinker cooling air prior to its use in boilers or other heat recovery systems. Moisture control or reduction for the raw materials using exhaust gases from heat recovery systems. Use of an alternate (conventional steam boiler or generator) CHP system for generating power using hot air from cooling beds as well as exhaust gases from the system. Opportunities for the Chemicals and Petroleum Refining Industries Heat recovery from low-temperature (<200°F or 95°C) but relatively clean gases, such as combustion products, from natural gas-fired heaters or boilers. Compact heat exchangers that allow condensation of water vapor and use mediums that use no or minimal water are needed. Treatment of high-temperature gases containing corrosive gases such as HCL from TO gases that includes removing (or reacting) these compounds while allowing heat recovery using conventional heat exchanger equipment. Equipment to recover heat from exothermic processes. The system must be compact and reliable and deliver recovered heat in the form of high-pressure steam or another compact usable form. Development of compact heat exchangers such as micro-channel heat exchangers for use in industrial environments. A major requirement is tolerance of the minor and unpredictable presence of solids or other materials that may adversely affect heat exchanger performance. Development of air-cooled heat exchangers that can replace water-cooled units. This will reduce water and associated energy use. Economically justifiable energy recovery from flared gases. R&D Opportunities by Research Category The industry requirement-based R&D lists have been consolidated to identify crosscutting R&D that could meet requirements of many different industries and at the same time fill the gaps in capabilities or performance of the currently available systems. While there are many ways the R&D areas could be presented, the following employs the method of dividing R&D activities into specific programs that can be pursued by equipment suppliers to advance the technology or performance of the currently offered systems: Industrial Waste Heat Recovery Page 39PDF Image | Industrial Waste Heat Recovery: Potential
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