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It has been a general rule of thumb in industrial operations that fluids with temperatures less than 248°F (120°C) (or, better, 300°F or 150°C to provide a safe margin), are set as the limit for waste heat recovery because of the risk of condensation of corrosive liquids. However, as fuel costs continue to rise, even such waste heat can be used economically for space heating and other low-temperature applications. It is possible to reverse the direction of spontaneous energy flow by using a thermodynamic system known as a heat pump. The majority of heat pumps work on the same principle as the vapor compression cycle. In this cycle, the circulating fluid (such as a refrigerant) is physically separated from the heat source (i.e. waste heat, at a higher temperature) and the fluid is re-used in a cyclical fashion, therefore being called “closed cycle.” In the heat pump, the following processes take place: In the evaporator, the heat is extracted from the heat source to boil the circulating substance. The compressor compresses the circulating substance, thereby raising its pressure and temperature. The low-temperature vapor is compressed by a compressor, which requires external work. The work done on the vapor raises its pressure and temperature to a level where its energy becomes available for use. The heat is delivered to the condenser. The pressure of the circulating substance (working fluid) is reduced back to the evaporator condition in the throttling valve, where the cycle is repeated. The heat pump was developed as a space heating system where low-temperature energy from the ambient air, water, or earth is raised to heating system temperatures by doing compression work with an electric motor-driven compressor. Heat pumps have the ability to upgrade heat to a value more than twice the energy consumed by the device. The potential for application of heat pumps is growing and a growing number of industries have benefited by recovering low grade waste heat, upgrading it, and using it in the main process stream. Heat pump applications are most promising when both the heating and cooling capabilities can be used in combination. One such example of this is a plastics factory where chilled water from a heat pump is used to cool injection-molding machines, while the heat output from the heat pump is used to provide factory or office heating. Other examples of heat pump installations include product drying in which the dry atmosphere for storage is maintained and compressed air is dried. Thermo-Compressor In many cases, for lack of a better option for reuse, very low-pressure steam is reused as water. However, it is feasible to compress this low-pressure steam by very high-pressure steam and reuse it as a medium-pressure steam. The major energy in steam is in its latent heat value, thus, thermo compressing would largely improve waste heat recovery. A thermo-compressor is simple equipment with a nozzle where high pressure (HP) steam is accelerated into a high velocity fluid. This entrains the low pressure (LP) steam by momentum transfer and then recompresses it in a divergent venturi. It is typically used in evaporators where the boiling steam is recompressed and used as heating steam. Thermally Activated Technologies (TAT) TAT consists of equipment use thermal energy for heating, cooling, humidity control, and power (mechanical and electric). These technologies include absorption chillers or refrigerating equipment, desiccant systems for humidity control, and organic Rankine type power generation systems. Many of the systems known as Combined Heat and Power (CHP) can be considered thermally activated technologies when they use waste heat for power generation. Industrial Waste Heat Recovery Page 56PDF Image | Industrial Waste Heat Recovery: Potential
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