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Supercritical carbon dioxide systems Thermo-electric power generation (TEG) The conventional systems for high-temperature waste heat applications use a heat recovery steam generator (HRSG) or boiler, steam turbine, and a generator to produce electricity. Other options are now available that can be used for lower temperature heat sources, including Organic Rankine Cycle (ORC), ammonia–water systems (i.e., Kalina, Neogen systems), Supercritical carbon dioxide systems, and Thermo-Electric Generators (TEG). This area is a fast-changing field. Technologies, performance, and costs can vary significantly. “Conventional Plant" Using a Steam Boiler, Steam Turbine, and Generator The steam-based systems require heat source (usually exhaust gases) higher than 600°F (315°C) to produce high-pressure steam. The gases have to be relatively clean without the presence of particulates, condensable vapors, or corrosive gases that would affect performance and life of the boiler interiors. Efficiency, defined as the ratio of electrical energy produced to the total heat input (sensible and chemical heat of exhaust heat source, plus auxiliary heat input if used), is in the range of 25%–30%. Most of these systems are available in large sizes (higher than 2 MW electrical output or total heat input of 25 MM Btu/hr). Therefore, they are used only for very large fired systems such as steel reheating furnaces, process heaters, cement or lime kilns, and certain steel melting furnaces. Following are other issues or barriers associated with conventional, steam-based, power generation systems: Need a relatively clean and contamination-free source of waste heat (gas or liquid source) – avoid heavy particulate loading and/or presence of condensable vapors in waste heat stream Need continuous or predictable flow for the waste heat source Need relatively moderate waste heat stream temperature (at least 300°F (150°C), but >600°F (315°C) is preferred) at constant or predictable value Cannot find or justify use of heat within the process or heating equipment itself Cannot find or justify alternate heat recovery methods (steam, hot water, cascading, etc.) that can be used in the plant Try to avoid or reduce use of supplementary fuel for power generation as it can have a negative effect on overall economics—unless the power cost can justify it As mentioned before, conversion efficiency of waste heat to electricity is low; therefore, it should only be considered when the heat cannot be used directly within the process or when other recovery methods are not practical within the plant. Overall economics of the system depends on the cost of electricity and, in some cases, on the benefits of reducing peak demand if the demand charges are high. It is advisable to avoid or reduce the use of supplementary fuel for power generation since this has negative effects on the overall economics. Industrial Waste Heat Recovery Page 59PDF Image | Industrial Waste Heat Recovery: Potential
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