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TA 6M: Waste Heat Recovery Limitations of Currently Available Technologies Table 6.M.8 and Table 6.M.9 depict limitations and barriers of currently available WHR technologies for ultra- high, high, and medium temperature ranges. Table 6.M.8 Limitations of Currently Available WHR Technologies, High and Ultra-High Temperature Ranges1 Equipment Limitations and Barriers Metallic recuperators Upper temperature limit of 1,600°F Economically justifiable heat recovery efficiency limit of 40% to 60%1 High maintenance costs for use with gases containing particulates, condensable vapors, or combustible material Reduced life expectancy in applications where the mass flow and temperature of the fluids vary or are cyclic Fouling and corrosion of heat transfer surfaces Difficulty in maintaining or cleaning the heat transfer surfaces Ceramic recuperators Reduced system life expectancy due to thermal cycling and the possibility of leaks from the high- pressure side High initial cost Relatively high maintenance Size limitations – difficult to build large size units Recuperative burners Lower heat recovery efficiency (usually less than 30%) Temperature limitation – exhaust gas temperature less than 1,600°F Limited size availability (usually for burners with less than 1 MM Btu/hr) Cannot be applied to processes where exhaust gases contain particles and condensable vapors Stationary regenerators Large system footprint Declining performance over time Plugging of exhaust gas passages when the gases contain particulates Chemical reaction of certain exhaust gas constituents with the heat transfer surfaces Possibility of leakage through dampers and moving parts Cost can be justified only for high-temperature (>2,000°F) exhaust gases and larger size (>50 MM Btu/hr firing rate) Rotary regenerators Seal failure between the high-pressure and low-pressure gases (air) Plugging of exhaust gas passages when the gases contain particulates High pressure drop compared to recuperators Maintenance and operation reliability issues for rotary mechanism Regenerative burners Large footprint for many applications Complicated controls with dampers that cannot be completely sealed Difficult pressure control for the furnace Cost competiveness Plugging of the bed when the gases contain particulates. Require frequent cleaning of the media and the bed. Heat recovery steam generators - boilers Limited to use for large size systems (usually higher than 25 MM Btu/hr) Limited to use with only clean and particulate-free exhaust gases Only viable for plants with need for steam use Initial cost is very high compared to other options such as recuperators 19 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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