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TA 6M: Waste Heat Recovery Air cooled (dry) heat exchangers to be used to replace or supplement currently used water cooled condensers or heat exchangers (see the Opportunities in Applied Research section, above, for heat transfer improvement). New concepts for recovering and collecting heat from gases containing particulates and high- temperature condensable materials as encountered in the glass, steel, cement, and aluminum industries. New regenerator designs to reduce the volume of high-temperature particulate laden gases, such as using a high surface-area-to-volume ratio or high thermal capacity materials that are easy to clean. Improved design of waste heat “boilers” that can utilize lower temperature (≥100°F) heat source. This allows use of “low grade” waste heat for thermally-activated refrigeration and heat pump systems to replace or supplement direct gas firing. Pumps and turbo-expanders with high turndown capability for use in low-temperature power generation systems. Self-cleaning filters for gases with relatively low particulate loading. Advanced heat exchangers for evaporators and condensers that are inexpensive to build, maintain, and operate compared to other furnace types of comparable heating capacity. Use of heat recovery absorption chillers for recovering waste heat from industrial process heating systems where currently heat is rejected to the cooling towers. Many industrial processes (and certainly most large commercial buildings) reject waste heat through cooling towers. At the same time, the same facility is generating hot water or steam for other needs. Waste heat from process heating systems could be used for generating hot water/steam or to drive the lithium bromide refrigeration cycle inside absorption chillers. Many studies28,29 show that use of heat recovery chillers results in overall energy reductions, as well as a cost reduction. Methods to seal ends of a continuous furnace or oven to reduce or eliminate air leaks that result in excessive energy use in heating equipment; increased size for exhaust gas handling systems; and gas treatment, if necessary for meeting local environmental regulations. Opportunities in Sensors and Controls R&D opportunities in sensors and controls include: Reliable sensors and controls for high-temperature (>400°F) applications to measure and monitor humidity or lower explosion limits (LEL) in dryers and ovens to allow for recycling of exhaust gases and reduce the amount of make-up air. Systems for monitoring heat exchanger performance to detect performance degradation maintenance issues. A low-cost reliable system for monitoring oxygen and carbon monoxide in small applications (<5 MMBtu/hr fired systems). Continuous monitoring of energy intensity (Btu or kWh per unit of production) to identify performance problems. Other sensor and controls R&D opportunities, including sensor integration challenges, are discussed in more detail in the 2015 QTR Technology Assessment 6.C Advanced Sensors, Control, Platforms, and Modeling for Manufacturing. 28 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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