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TA 6M: Waste Heat Recovery the corrosive gases and metal tubes in a recuperator could result in an extremely short life for the recuperator. The use of advanced materials that would extend the recuperator life is currently uneconomical for most applications. 3. Presence of particulates (e.g., metal oxides, carbon or soot particles, fluxing materials, slag, aluminum oxide, magnesium oxide, manganese): Fine particles entrained in flue gases may react with the heat exchanger materials (metallic or nonmetallic), resulting in reduction of heat transfer and in damaging reactions with heat exchanger materials. The net effect of these reactions is a shorter life for recuperator parts and, often, premature failure of metals at critical locations. In some cases, such as in boilers, it is possible to remove the material buildup by periodic maintenance to remove soot, but this is not practical for all types of heat recovery systems. 4. Presence of combustibles (e.g., CO, H2, hydrocarbons): As mentioned above, the presence of combustibles in flue gases could result in higher-than-design temperatures for heat exchangers owing to air leaks or the addition of dilution or cooling air to flue gases. In cases where no cooling or dilution air is used, the presence of combustibles can still present severe problems. The combustibles may react with constituents (such as nickel) of high-temperature alloys to form soot that deposits on heat transfer surfaces and reacts with metal, leading to shortened life of equipment components. 5. Presence of combustible volatiles from charge material such as scrap used for aluminum melting furnaces and EAF: The scrap is obtained from a variety of sources and the plants use separation processing of scrap to remove combustible materials such as oils, paint, paper, plastic, and rubber. However, some of these materials end up in the charge material. Incomplete combustion, or breakdown of these organic materials results in the presence of combustible gases or solids, and they have the same effects on heat recovery equipment as the combustible materials described in item.4 6. Variations in flow, temperature and composition of gases: Large industrial heating equipment that uses a large amount of energy, such as EAFs, BOFs, and many aluminum melting furnaces, operate in a batch or semi-continuous mode. This results in variations in temperature, flow, and the composition of flue gases leaving the furnace. Variations in flue gases could result in cycling of materials (metal, in the case of a recuperator) and thermal fatigue of metals used in the heat recovery equipment. Thermal fatigue reduces the life of materials. At this time the industry uses several practices for managing or dealing with exhaust gases classified as harsh environments: 1. No heat recovery, but treating (scrubbing, cooling by blending with cold air or mist cooling) exhaust gases to meet regulatory requirements. Examples are EAF and BOF exhaust gases. 2. Partial WHR due to materials limitations, design issues, and space considerations. An example is preheating of glass melting furnace combustion air using regenerators. 3. Partial WHR due to other limitations such as safety, maintenance, lifetime. Examples are use of scrap preheaters for EAFs and use of steam generation for BOF installations. 4. Partial or no WHR due to high capital cost, limited operating hours, or other operating and economic reasons. Examples are small glass and aluminum melting furnaces and cement and lime kilns. 12 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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