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TA 6M: Waste Heat Recovery Heat recovery from very high temperature gases (2,200°F) that contain condensable vapors and produce solid particles that need to be removed. Possible methods include fluidized bed or solid particle-gas heat transfer with a proper material handling system. Quenching methods for hot gases to control generation of condensates, and subsequent use of these clean gases in conventional boilers or air heaters. Electricity generation through direct contact or radiation from moderate temperature (300°F – 900°F) surfaces with economically justifiable paybacks. Possible methods are thermoelectric and thermophotovoltaic devices under development. Use of advanced heat exchangers for evaporators and condensers that use direct gas-air heating for the evaporators, and air for condensers. This would eliminate secondary heat exchanger loops that utilize hot water or steam for the evaporators, as well as the need for cooling towers for the condenser. This simplified approach would reduce costs as well as eliminate inefficiencies introduced with the use of secondary heat exchanger circuits. Secondary heat recovery systems for flue gases discharged from regenerators. These gases are at temperatures in the range of 800°F – 1,200°F. The gas temperature is cyclic and, in some cases, the gases contain very small amount of particulates, which are easy to remove. Glass batch drying and preheating systems using exhaust gases from the melting furnace or refining forehearth section exhaust gases. Previously developed systems have not been used by the industry due to a variety of issues related to operations and maintenance. A new approach or design is required. Hot gas cleanup systems for use by medium- to low-temperature gases prior to secondary heat recovery. Use of CHP systems for generating hot gases for use in annealing ovens. The system will deliver electricity as well as hot air with low oxygen for use as combustion air. Use of heat from annealed products. The heat is available at temperatures below 500°F. Considerations for Coating Plants or Paint Shops WHR related R&D consideration for the Coating Plants or Paint Shops include: Secondary heat recovery from regenerative thermal oxidizer (RTOs) exhaust gases that are available from 350°F – 400°F. Control system for ovens to regulate the amount of make-up air used. This will require development of a system that controls the amount of make-up air, and hence the amount of heat wasted from the oven. Endnotes 1 Oak Ridge National Laboratory (ORNL), Industrial Waste Heat Recovery: Potential Applications, Available Technologies and Crosscutting R&D Opportunities, Arvind Thekdi (E3M Inc.) and Sachin Nimbalkar (ORNL), ORNL/TM-2014/622, January 2014. Available at: http://info.ornl. gov/sites/publications/files/Pub52987.pdf. This report provides a current, comprehensive assessment of WHR technologies, and sections of this report are excerpted in this Technology Assessment. 2 Large amounts of particles or condensable vapors can impede the performance of heat recovery technologies. 3 Energetics Incorporated and E3M, Incorporated, Energy Use, Loss and Opportunities Analysis: U.S. Manufacturing & Mining, prepared for the U.S. Department of Energy, Industrial Technologies Program, December 2004. Available at: http://energy.gov/sites/prod/files/2013/11/f4/ energy_use_loss_opportunities_analysis.pdf 4 BCS, Incorporated, Waste Heat Recovery: Technology and Opportunities in U. S. Industry, prepared for the U.S. Department of Energy, Industrial Technologies Program, March 2008. Available at: http://www1.eere.energy.gov/manufacturing/intensiveprocesses/pdfs/waste_heat_recovery.pdf 5 Pacific Northwest National Laboratory (PNNL), Opportunity Analysis for Recovering Energy from Industrial Waste Heat and Emissions, prepared for the U.S. Department of Energy, April 2006. Available at: http://www.pnl.gov/main/publications/external/technical_reports/PNNL-15803.pdf 6 Lawrence Berkeley National Laboratory (LBNL), Energy Efficiency Improvement and Cost Saving Opportunities for Petroleum Refineries: An ENERGY STAR® Guide for Energy and Plant Managers, prepared for the U.S. Environmental Protection Agency, February 2015. Available at: http://www.energystar.gov/sites/default/files/tools/ENERGY_STAR_Guide_Petroleum_Refineries_20150330.pdf 33 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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