Industrial Waste Heat Recovery: Potential

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Industrial Waste Heat Recovery: Potential ( industrial-waste-heat-recovery-potential )

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Typical industrial applications are heat recovery from ventilation, air conditioning, and low-temperature heat recovery. Low-Temperature Waste Heat Recovery Systems With a few notable exceptions, most low-temperature heat exchangers are constructed from copper tubing with aluminum fins soldered or press-fitted on the outside surface of the copper tubes. The tubes are bent in the hairpin shape to provide longer residence time for the fluid flow inside the tube. Both of these design features improve heat transfer. In addition, low-temperature waste heat recovery systems have several new features that offer higher heat transfer rates, such as special fin designs for finned tube heat exchangers and redesigned tube-on-plate condensers with Coanda-effect louver designs that allow the air to flow in wave form. Plastic Heat Exchangers New plastic heat exchangers developed by several suppliers offer an alternative to metal heat exchangers as metal exchangers are subject to corrosion, oxidation, and microbiological attack and experience slow degradation and loss in heat transfer capacity when used in chemical water treatment. Use of specialized plastics for heat exchanger tubing provides effective energy transfer in most applications. Some suppliers claim that the heat transfer capacity of this plastic tubing is comparable to that of copper heat exchangers, and that transfer rate remains consistent for both heating and cooling. These heat exchangers are not subject to corrosion, oxidation, microbiological attack, or galvanic action. This allows the plastic heat exchangers to function effectively under conditions in which conventional systems would not survive. Additionally, friction or contact between coils during operation is not an issue because: 1) the coils naturally dampen the vibrations in the system and 2) the surface is smoother, permitting little friction between tubing rows even if they do come in contact. Also, plastic is lightweight and its surface is smoother than copper and resists the buildup of material deposits, which can restrict both fluid and airflow through and around the coils. If an internal buildup does occur, it can be removed by flushing the plastic at moderate pressure. Despite their significant advantages, plastic heat exchangers are not suitable for all applications. They cannot be used with refrigerants or high-pressure or high-temperature systems. Plastic is not a suitable heat transfer media for systems with operating temperatures higher than 220°F (105°C) or pressures higher than 150 psi. Plastic additionally cannot be used with any gaseous systems because it does not serve as a sufficient vapor barrier. Direct Contact Water Heaters The direct contact water heaters are used to heat water using sensible and latent heat of exhaust gases. In many cases, the latent heat represents more than 10 times the sensible heat. A typical direct contact water heater, shown in Exhibit A-13, is used to recover heat from a boiler’s exhaust gases. Colder water from the process enters the top inlet of the water heater (economizer) and is sprayed over the heat transfer media. Simultaneously, the hot exhaust gas or boiler flue gas is directed to the flue gas inlet, at the base of the economizer. The water travels from the spray nozzle counterflow, from the rising flue gas through the stainless steel transfer media. As the water droplets travel through the media, the hot flue gas rises to the top of the economizer, preheating the water. Industrial Waste Heat Recovery Page 54

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