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TA 6M: Waste Heat Recovery Technologies and Materials for Recovering Waste Heat in Harsh Environments16 The Technologies and Materials for Recovering Waste Heat in Harsh Environments report16 identified industries and industrial heating processes in which the exhaust gases are at high temperature (>1,200°F), and contain reactive gases, liquid vapors, volatiles from low-melting-temperature solid materials, particulates, or condensable materials. It also identified specific issues related to WHR for each of these processes or waste heat streams. In addition to this study, the 6.H Materials for Harsh Service Conditions Technology Assessment which is available as an appendix to the 2015 Quadrennial Technology Review (QTR) expanded in more detail on some of issues summarized here. Key insights from the report are excerpted below. The temperature of the exhaust gases discharged into the atmosphere from heating equipment depends on the process temperature and whether a WHR system is used to reduce the exhaust gas temperature. The temperature of discharged gases varies approximately from as low as 150°F to as high as 3,000°F. Combustion products themselves, generated from well-designed and well-operated burners using gaseous and light liquid fuels, are relatively clean and do not contain particles or condensable components that may require “cleanup” before discharge into the atmosphere. However, during the heating process, the combustion products may react or mix with the product being heated and may pick up constituents such as reactive gases, liquid vapors, volatiles from low-melting-temperature solid materials, particulates, condensable materials, and the like. Some or all of these constituents, particularly at high temperatures, may react with materials used in the construction of downstream WHR equipment and create significant problems. Potential issues include chemical reaction of exhaust gases and their solid or vapor content with the materials used in the WHR equipment; deposition of particulates in or on surfaces of WHR equipment; condensation of organics such as tars and inorganic vapors such as zinc oxides and boron on heat exchanger surfaces; and erosion of heat exchanger components by the solids in the exhaust gases. Many of these problems are compounded by the high temperature of the exhaust gases, uneven flow patterns of the hot gases inside the heat exchanger, and operating variations such as frequent heating and cooling of the heat exchanger. The study identified industries and heating processes in which the exhaust gases are at high and ultra-high temperatures (>1200°F), contain all of the types of reactive constituents described, and can be considered as harsh or contaminated. The study also identified specific issues related to WHR for each of these processes or waste heat streams. The following are common characteristics of the conditions classified as harsh environments: 1. Ultra-high gas temperature (>1,600°F): Even if the process temperature is less than 1,600°F, the presence of combustible components such as CO, H2, or hydrocarbons in flue gases could increase localized temperatures to exceed the temperature limit of the heat recovery system components. An example is when combustible components are in the presence of air that could leak into the flue gas ducts or into a WHR system such as a recuperator; examples might include electric arc furnace (EAF) and basic oxygen furnace (BOF) exhaust gases, and flue gases from “over-fired” aluminum melting furnaces. 2. Presence of highly corrosive fluxing agents (e.g., salts, calcium, chlorides, fluorides): The types and amounts of fluxing agents or their compounds depend on the heating process and the final product specifications. These fluxing agents introduce highly corrosive elements that promote degradation of WHR equipment materials. For example, chemical reactions between 11 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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