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980°C) due to limitations (technical and economical) of the material used in the recuperators. Early ceramic recuperators were built of tile and joined with furnace cement; however, thermal cycling caused cracking of joints and rapid deterioration of the tubes. Recent developments in ceramic recuperators use silicon carbide tubes, which can be joined by flexible seals located in the air headers. These designs require good seal design to avoid leakage of combustion air which is at a higher pressure. The new designs are available in many different configurations and now offer much improved performance in terms of heat recovery and life. External recuperators are among the most widely used heat recovery devices; however, their use is limited due to several factors: Temperature limit for metallic recuperators. The limit depends on the material used for the recuperator construction. Modern recuperators that use high-temperature alloys can be used with flue gas temperatures up to 1,600°F (870°C). Cost of high-temperature recuperators. The alloys used for gases above 1,200°F (650°C) can be very expansive. For example, the cost of a recuperator used for exhaust gases at 1,600°F (870°C) can be in the range of $10,000–$15,000 per MM Btu recovered. The recuperators cannot be used for gases that contain particulates, corrosive gases, and condensable vapors. Ceramic recuperators require high maintenance due to potential for air leaks and and for material damage during thermal cycling. Self-recuperative Burners A special class of recuperators, known as self-recuperative burners, is now offered by several burner suppliers. In this system, the recuperator is integrated with the burner itself, so there is no need to have hot air piping from the recuperator to the burners resulting in substantial cost advantage. Exhibit A-3 shows commonly used designs for direct fired burners and radiant tube type heating systems. Exhibit A-3: Self-Recuperative Burner Designs (Direct Fired and Radiant Tube Application) The self-recuperative burners cannot give the same heat transfer rate or heat transfer efficiency; hence the fuel savings are limited to 30%–60% of that normally available from an external recuperator. Regenerators Regenerators have been widely used in glass and steel melting furnaces to recover heat from high- temperature exhaust gases, normally above 2,500°F (1,370°C). They are made from high-temperature refractory bricks or specially designed ceramic shapes. The efficiency of the regenerator depends on the size of the regenerator; the time span between reversals; and the thickness, conductivity, and heat Industrial Waste Heat Recovery Page 46PDF Image | Industrial Waste Heat Recovery: Potential
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