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TA 6M: Waste Heat Recovery Systems with smaller footprints that allow retrofit installation for existing systems that are typically space-constrained in plants. Secondary heat recovery systems that can be used as supplementary or secondary recovery systems to enhance the performance of the existing systems. These systems should be compatible with the performance of the primary systems. A hot gas cleaning system with anti-fouling and anti-clogging capabilities to remove particulates from high-temperature gases, prevent fouling and corrosion of heat transfer surfaces, and reduce system maintenance requirements. Electrical power generation systems integrated with high-temperature waste heat sources or existing primary heat recovery systems. The electric power generation system must be able to handle variations in heat sources and the cyclic nature of the waste heat source. In most cases, the system must be able to tolerate some contaminants present in the waste heat source. Catalysts for reforming fuel gases or liquid fuel vapors for use in endothermic heat recovery units. Opportunities for Medium-Temperature Waste Heat Sources R&D opportunities for medium temperature waste heat sources (600°F – 1,200°F) include the following: Compact heat exchangers or micro-channel heat exchangers for clean gases that reduce the size or footprint of the heat recovery system, enabling the development of more cost-effective systems and greater adoption in applications that are space-constrained. High-performance heat recovery systems that integrate burners and eliminate the need for hot air piping and space for external heat recovery systems. This may require development and integration of micro-channel heat exchangers. Heat transfer systems for gases containing condensable vapors or combustible gases such as solvent vapors in coating ovens. This would reduce material corrosion issues, increase the life of the WHR systems, and reduce greenhouse gas emissions. Opportunities for Low and Ultra-Low Temperature Waste Heat Sources R&D opportunities for both low temperature waste heat sources (250°F – 600°F) and ultra-low temperature waste heat sources (<250°F) include the following: Condensing heat exchangers for gases containing high moisture levels with particulates, as discharged from paper machines, food drying ovens, or other sources. By addressing design and material issues associated with the existing condensing economizers, it would be possible to increase WHR below condensing temperatures in paper machines, food drying ovens, or other sources. Nonmetallic materials (polymers) that can withstand condensed water from combustion products containing acid gases. R&D of advanced polymers and composite materials would help in developing innovative WHR concepts. Efforts needs to be taken to make these materials more cost competitive. High-efficiency, liquid-gas heat exchangers for low-temperature flue gases or exhaust air from dryers. Liquid-to-liquid heat exchangers for heat recovery from waste water containing particulates and other contaminants. This would involve R&D in innovative designs and advanced materials. Dry coolers for cooling liquids that reduce or eliminate water use in heat exchangers. Operating and maintaining cooling water loops and towers is expensive. Air to liquid heat exchangers eliminate need for cooling towers and cooling loops. A special category of heat recovery systems includes use of waste heat for electric power generation systems and absorption cooling systems for low- and medium-temperature WHR. R&D needs for this category of WHR systems include the following: 21 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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