Waste Heat and Water Recovery System Optimization for Flue Gas

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Waste Heat and Water Recovery System Optimization for Flue Gas ( waste-heat-and-water-recovery-system-optimization-flue-gas )

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Sustainability 2019, 11, 1881 2 of 20 recovery where a great deal of research is being done on materials [8] as well as at a system level, but the conversion efficiencies are still below 5% [9]. The power produced by several heat recovery and renewable technologies are generally on a small scale and variable. Investigations are also being conducted to utilize the harvested power by using smart and efficient grid and electrical distribution systems which can reduce the power loss at the consumer end [10,11]. The organic Rankine cycle (ORC) is among the power cycles widely used for conversion of recovered waste heat to electrical power. Power plants based on the ORC produce power from various heat sources. These power plants range in size from 300 kW to 130 MW and have demonstrated the maturity of this technology. The cycle is well adapted for low to moderate temperature heat sources, such as waste heat from industrial plants. ORC technology is applicable to heat recovery from medium-sized gas turbines and offers significant advantages over conventional steam bottoming cycles [12]. ORCs can function in combination with low-temperature heat sources, characterized by low to moderate evaporation pressure, and still achieve better performance than steam cycles. The heating curves of ORCs can be better matched to the temperature profiles of waste heat sources, resulting in higher cycle efficiencies and higher thermal power recovery ratios than steam bottoming cycles [13]. Over the years, the ORC has been applied to waste heat recovery from different heat sources [14,15] which have also included automobile engines [16] and power plant flue gas. Koc et al. [17] analyzed a geothermal ORC from an energy and economical point of view. Liu et al. [18] on the other hand, utilized the high-grade sensible heat of a natural gas boiler present in the flue gas using the ORC, while the low-grade sensible heat and latent heat were recovered by working with fluid condensation and cooling water absorption. Currently, fossil-fuel-based power plants consume vast quantities of water for heat rejection, fuel preparation, power augmentation, emission control, and cycle makeup purposes. At the same time, global water resources are becoming more difficult to procure as water consumption exceeds renewal [19]. Cooling systems are the most water-intensive portion of the thermoelectric generation process, presenting significant opportunities to reduce withdrawal and consumptive use of fresh water. Reuse of impaired water for cooling can reduce freshwater withdrawal and decrease water contamination as well as withdrawal-related impacts on aquatic life and the environment [20]. With the increasing trend of waste heat recovery technologies for fossil-fueled power plants, the need for water recovery from flue gas is also being seriously considered. There is a need to reduce the amount of fresh water needed for cooling purposes to enable power plant operation in more arid regions [21]. One of the methods of water recovery was investigated by Shen et al. [22], as it presented membrane technology as a potential means for water recovery from the flue gas of a lignite boiler. Similarly, Wang et al. [23] investigated a ceramic membrane suggesting that an increase in flue gas humidity can dramatically improve water and heat transfer rates and the overall heat transfer coefficient, offering a general guideline to optimize the operational parameters in low-grade heat recovery using membrane heat exchangers. Zhang et al. [24] presented the idea of reducing the flue gas temperature below the dew point of the water vapor within it to simultaneously recover latent heat and obtain clean water. The heat transfer mode of this method is a direct contact mode that utilizes the flue gas desulfurization scrubber as a flue gas water vapor condensing heat exchanger. Similarly, Bilirgen et al. [25] developed an analytical model for a flue gas condensing heat exchanger system to predict the heat transferred from the flue gas to the cooling water and the water vapor condensation rate in the flue gas. Vapor condensation from flue gas via air cooling has also been studied [26]. Other than recovering flue gas contents, heat recovery and water condensation from flue gas can help reduce emissions to the environment. In the past, researchers have focused on filterable particulate matter (FPM) because of its large emission amounts. Such active research prompted the rapid development of FPM control technology. At present, FPM is effectively controlled, and its emission concentration is extremely low. In contrast, the emission concentration of condensable particulate matter (CPM) is higher than that of FPM and requires immediate attention. Therefore, researchers are paying close attention to CPM. Nevertheless, CPM remains poorly understood [27]. Jeong et al. [21]

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