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3.2 Opened-circuit schemes of waste heat utilization

These systems are usually used for low-temperature heat waste utilization. Much industrial waste heat is in the low­temperature range. For example, combustion systems such as boilers frequently use recovery technologies that exhaust gases at around 150°­180°C. Meanwhile, large quantities of waste heat can be found in industrial cooling water and cooling air.

In the case of combustion exhaust gases, substantial heat can be recovered if water vapor contained in the gases is cooled to lower temperatures. Minimum temperature limits around 120­150°C are frequently employed in order to prevent water in the exhaust gases from condensing and depositing corrosive substances on the heat exchanger surface. However, cooling the flue gas further could significantly increase heat recovery by allowing the latent heat of vaporization to be recovered. This latent heat comprises a significant portion of the energy contained in exhaust gases. Technologies that can minimize chemical attack while cooling exhaust gases below the condensation point can achieve significant increases in energy efficiency via recovering the latent heat of evaporation. If gases are cooled from 150°C to 60°C, then the facility can obtain a 3% efficiency increase. Cooling gases further 38°C captures a portion of the latent heat and can provide an 11% efficiency increase.

Low­temperature heat recovery faces at least three challenges:

  • corrosion of the heat exchanger surface: As water vapor contained in the exhaust gas cools, some of it will condense and deposit corrosive solids and liquids on the heat exchange surface. The heat exchanger must be designed to withstand exposure to these corrosive deposits. This generally requires using advanced materials, or frequently replacing components of the heat exchanger, which is often uneconomical;

  • large heat exchange surfaces required for heat transfer: Heat transfer rates are a function of the thermal conductivity of the heat exchange material, the temperature difference between the two fluid streams, and the surface area of the heat exchanger. Since low­temperature waste heat will involve a smaller temperature gradient between two fluid streams, larger surface areas are required for heat transfer. This limits the economics of heat exchangers;

  • Finding a use for low­temperature heat. Recovering heat in the low­temperature range will only make sense if the plant has a use for low­temperature heat. Potential end­uses include domestic hot water, space heating, and low­temperature process heating. Other options include using a heat pump to “upgrade” heat to a higher temperature to serve a load requiring higher temperatures.

Technologies are available that can cool gases below dew point temperatures to recover low­temperature waste heat. Options include deep economizers, indirect contact condensation recovery, direct contact condensation recovery, and recently developed transport membrane condensers. Commercialization has been limited due to high costs and because facilities lack an end­use for the recovered heat. When facilities lack an end­use for waste heat, some have found other means for recovery, including heat pumps and low­temperature power generation. These technologies are also frequently limited by economic constraints.

Deep Economizers

Deep economizers are designed to cool exhaust gas to 65°C­71°C and to withstand the acidic condensate depositing on its surface. Designs include the following options:

  • installing a “throwaway” section on the cold end of the economizer. The tubing in the cold end will degrade over time and will need to be repeatedly replaced. The frequency of replacements will depend on the flue gas composition and the material of construction;

  • designing the economizer with stainless steel tubes. Stainless steel can withstand acidic gases better than the mild steel typically used in construction;

  • using carbon steel for the majority of the heat exchanger, but using stainless steel tubes in the cold end where acidic deposits will occur;

  • using glass­tubed heat exchangers (mainly for gas­gas applications such as air preheaters);

  • using advanced materials such as Teflon.

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