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TA 6M: Waste Heat Recovery Table 6.M.11 Summary of Waste Heat By Type and Associated Barriers1 Type of Waste Heat Associated Barriers to Adoption in U.S. Industry High-temperature combustion products or hot flue gases that are relatively clean Reduced thermodynamic potential for the most efficient heat recovery due to materials limitations (particularly metallic) that require gases to be diluted Heat transfer limits on the flue gas side in steam generation or other power generation (i.e., organic Rankine cycle) heat exchanger systems applications Seal issues for heat exchanger designs with metallic and nonmetallic (ceramics) components (due to dissimilar thermal expansions) High-temperature flue gases or combustion products with contaminants such as particulates or condensable vapors Availability or cost of materials that are designed to resist the corrosive effects of contaminants Lack of design innovation that will allow self-cleaning of the heat recovery equipment to reduce maintenance Lack of cleaning systems (similar to soot blowing) that allow easy and on-line removal of deposits of materials on heat transfer surfaces Heat transfer limitations on the gas side of heat exchange equipment Heated air or flue gases containing high (>14%) O2 without large amounts of moisture and particulates Limitations on the heat exchanger size that prevent use on retrofit, which may be due to heat transfer limitations or design issues such as size and shape of heat transfer surfaces (e.g., tubes or flat plates) Lack of availability of combustion systems for small (less than 1 MMBtu/hr) sizes to use low O2 exhaust gases as combustion air for fired systems Process gases or by-product gases and vapors that contain combustibles in gaseous or vapor form Lack of available, economically justifiable vapor concentrators for recovery and reuse of the organic-combustible components, which would avoid the need for heating a large amount of dilution air and the resultant large equipment size. The concentrated fluids can be used as fuel in the heating systems (ovens). Lack of availability of compact heat recovery systems that will reduce the size of the heat exchangers (large regenerators) Process or make-up air mixed with combustion products, large amounts of water vapor, or moisture mixed with small amount of particulates but no condensable organic vapors Rapid performance drop and plugging of conventional heat exchanger. Unavailability of designs that allow self-cleaning of heat transfer surfaces on units such as recuperators. Lack of innovative designs that allow use of condensing heat exchangers (gas-water) without having the corrosive effects of carbonic acid produced from CO2 in flue products Steam discharged as vented steam or steam leaks No major technical barriers. The major barriers are cost and return on investment for the collection of steam, the cooling system, condensate collection and, in some cases, the cleaning system. Other gaseous streams Application-specific barriers Clean heated water discharged from indirect cooling systems such as process or product cooling or steam condensers. This stream does not contain any solids or gaseous contaminants Lack of opportunities to use low-grade heat within the plant. Lack of economically justifiable heat recovery systems that can convert low-grade heat into a transportable and usable form of energy, such as electricity. 24 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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