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TA 6M: Waste Heat Recovery Reactive systems (i.e., controlled combustion for organic vapors) to remove or collect organic vapors and combustible gases or vapors with controlled reaction rates and temperature increases. This includes developments in regenerative thermal oxidizers, catalytic oxidizers, and direct thermal oxidizers.24 Opportunities in Advanced Materials WHR systems employ both metallic and nonmetallic materials with a variety of technical limitations. R&D opportunities in advanced materials include: Coating materials with greater thermal stabilities for higher temperature applications; reduced wear, and easier repair.20 Corrosion-resistant coatings for low-temperature applications. High-temperature (>1,600°F) corrosion resistant materials for heat exchangers (recuperators). Heat storage materials with high latent heat, thermal capacity (specific heat), and thermal conductivity for all temperature ranges. Seal materials for high-temperature heat exchanger designs with moving parts (e.g., heat wheels or regenerators). The seal can be for metal-to-metal interface or metal-to-non-metallic materials (e.g., ceramics). Polymers or plastics with improved thermal conductivity for use in low-temperature corrosive environments (e.g., combustion products of fossil fuels). For example - ultra-high molecular weight polyethylene (UHMWPE) material for heat exchangers.25 Cost-effective thermoelectric or thermoionic materials capable of producing electricity from heat with 15%–20% thermal efficiency. For example, future figure of merit (ZT) of 1.8, compared to 1 in 2011, leading to greater conversion efficiencies; thermal stability up to 1000°C.20 As part of the 2015 QTR, a detailed evaluation of the potential of thermoelectrics is presented in the 6.G Direct Thermal Energy Conversion Materials, Devices, and Systems Technology Assessment. Working fluids for low-temperature power generation cycles that can withstand broader temperature ranges for use in ovens and furnaces. This also includes performance optimization of power generation cycles using low-global warming potential fluids (low GWP fluids). For example improving performance of regenerative supercritical ORCs (organic Rankine cycles) using low-GWP organic compounds as working fluid.26 Advanced materials to increase temperature lift in absorption cycles and improve overall heating and cooling performance. Catalysts to support lower temperature “reforming” reactions for use in medium- to high-temperature (≥800°F) waste heat applications. Higher temperature materials to be used for “bag-houses,” or gas cleaning systems. This will allow use of lower temperature electricity generation cycles. Opportunities in Advanced Concepts and Designs For maximum WHR, it is necessary to develop advanced concepts and new designs for WHR equipment. R&D opportunities include: Innovative heat transfer methods and heat exchanger geometries to reduce heat exchanger size (see the Opportunities in Applied Research section, above). Heat exchangers or regenerators with continuous surface cleaning to remove surface deposits resulting from particulates or fibers in waste gas streams. 27 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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