energy efficiency and advanced heat recovery technologiesenergy efficiency and advanced heat...
TRANSCRIPT
Energy Efficiency and Advanced HeatRecovery Technologies
Helen Skop and Yaroslav Chudnovsky
AbstractEnergy security is a global problem of any country worldwide. That is whyincrease in energy efficiency of industrial and commercial operations, implemen-tation of energy-saving approaches and smart energy management guarantee ofsuch a security, and, as a result, accelerating an economic growth. Energyeconomy strictly depends on energy intensity – the amount of energy used perGDP (gross domestic product). According to the multiple assessments by theInternational Energy Agency, the global process on energy intensity reduction isstill too slow and is not uniform across the globe. That is why the research andengineering community worldwide for the last decades has been focusing on theinnovation technologies on energy recovery and reuse for further efficiencyimprovement.
Contents1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 It Is All About Saving Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 Waste Heat Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.3 Rules of Thumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.4 Appropriate Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.5 State-of-the-Art Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.6 Integrated Use of Waste Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Cross-References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
H. Skop (*)Smart Heat Corporation, Skokie, IL, USAe-mail: [email protected]
Y. ChudnovskyGas Technology Institute, Des Plaines, IL, USAe-mail: [email protected]
# Springer International Publishing AG 2017F.A. Kulacki (ed.), Handbook of Thermal Science and Engineering,DOI 10.1007/978-3-319-32003-8_35-1
1
1 Introduction
The rapid development of industry and the growth of the world population, com-bined with the limitation of traditional fossil energy resources, forced the mankind inthe middle of twentieth century to consider energy saving and energy efficiency asthe top economic priority. The active implementation of programs aimed at increas-ing energy efficiency in the world began in the 1970s. Since that period, most of theindustrially developed countries have adopted relevant regulations and standards.The major trends in energy consumption projected to 2040 depending on thescenario are illustrated in Fig. 1.
Energy efficiency has a critical role to play for the sustainable development andhuman prosperity. Energy efficiency measures have the strong potential to achieve
1980
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Industrial energy consumptionquadillion British thermal units
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2016history projections
projectionshistory
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Low EconomicGrowth
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Fig. 1 Energy consumption trends: total and industrial (U.S. EIA Energy Outlook 2017)
2 H. Skop and Y. Chudnovsky
almost 50% in GHG (greenhouse gases) emissions reductions by 2030 as set out inthe Paris Agreement on Climate Change. Our everyday lives are getting more andmore dependable from the reliable and affordable energy services in order tofunction smoothly and to develop equitably. A well-established energy systemsupports all sectors ranging from businesses, medicine, and education to agriculture,infrastructure, communications, and process technology. At the same time, the lackof access to energy supplies is a major constraint to human and economic develop-ment. So with its ability to support energy security, environmental protection, andeconomic productivity, energy efficiency is in the best interest of every country,available in abundance to all.
Despite many efforts and techniques available on themarket nowadays, there is stilla huge untapped energy efficiency potential around the world. As clearly indicated in(IEA 2016) the global energy intensity (measured as total primary energy supply perunit of gross domestic product) improved by 1.8% in 2015 and 1.5% in 2014 – triplethe average improvement of 0.6% between 2003 and 2013 as illustrated in Fig. 2.
These energy intensity improvements were achieved even at the recent significantdecrease in crude oil price. However, global annual intensity needs to improve by 2.6%per year between 2016 and 2030 to achieve the established climate change goals. Moredetails, scenarios, and projections to 2040 can be also found in (IEA 2016).
Obviously, the energy efficiency market will grow in the coming years. Mergersand acquisitions of energy efficiency service firms have been increasing, withutilities, technology developers, technology providers, and energy equipment man-ufacturers all stepping up into this market. Terms “energy efficiency” and “energysavings” are often mentioned together. Though there is some interrelation, never-theless they are different terms. The term “efficiency” is related to getting a neces-sary result by using the smallest possible quantity of energy. The “savings,”however, means consumption of smaller quantity of energy compared to the bench-mark. Efficiency often leads to the savings of energy, but not to the contrary. Forexample, instead of using 100 W bulb within 10 h, it is possible to use a light-
2014 2015 2016-30(INDC)
2016-30(450S)
2000 2005
OECD
Notes: CAGR = compound annual growth rate; toe = tonnes of oil equivalent; 450S = 450 Scenario. Energy intensity iscalculated as TPES per thousand 2010 USD of GDP at market exchange rates. Sources: IEA (2015), World Energy Outlook, OECD/IEA: Paris; IEA (2016a), “World energy balances”, IEA World EnergyStatistics and Balances (database), DOI: http://dx.doi.org/10.1787/data-00512-en.
non-OECD 450 scenario
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Fig. 2 Changes in energy intensity from 2003 to 2030 by region and by scenario (IEA 2016)
Energy Efficiency and Advanced Heat Recovery Technologies 3
emitting diode (LED) lamp equivalent that consumes just 16 W for the same period.For 10 h of illumination, it will run out 0.16 kWh the electric power in comparisonwith 1 kWh, necessary for a conventional bulb. Thus, energy efficiency leads toconservation of energy and lowering of the utility bill.
Energy efficiency significantly varies across multiple industries and differentapplications, but one of the major energy losses is thermal energy loss, so-calledwaste heat. Sources of the waste heat comprise of a variety of gaseous exhausts,waste process liquids, cooling media, chemical wastes, and environmental losses.Over 30 years, the engineering community has been trying to develop cost-effectiveapproaches for waste heat recovery and utilization. The most popular recycling ofindustrial waste heat, known by engineers as “bottoming cycle cogeneration,”converts waste energy streams into electricity, steam for process heating, energyfor cooling, etc. Those waste streams include hot and humid exhausts, high-pressuregas, or steam that must be deflated. High-temperature exhausts are often availablefrom a wide spectrum of industrial processes such as coke ovens, glass furnaces,petrochemical processes, calcinations, and steel reheat furnaces. The heat from thoseexhausts (otherwise wasted to the environment) can produce steam to drive turbinegenerators and produce electricity. In addition to waste heat, some industrialexhausts are volatile (from blast furnaces, refineries, coke ovens, or chemicalprocesses), so they can also be combusted in boilers to produce additional steamto drive turbines and generate electricity or be used as a primary fuel for stationaryprimary movers. Such industrial energy recycling is well proven via multiplecommercially available technologies, with over 10 GW currently in use in the UnitedStates. Needless to say that about 20% to 50% of energy consumed in industrialmanufacturing is ultimately lost via waste heat contained in hot gaseous and liquidexhausts, as well as through other losses to the environment. There are still a lot ofopportunities for adoption of available technologies and for development of newones, because there is still no universal and cost-effective solution for the industrialwaste heat recovery and utilization.
1.1 It Is All About Saving Energy
Waste heat recovery and utilization attracted the attention of engineering communityin the middle of the last century right after World War II when the intensive growthand development of the industry identified the trends of energy efficiency improve-ment. Moreover, some reassignment of the European markets led to strategy devel-opment on energy efficiency and smart utilization of the available energy resources.As shown in Fig. 3, the energy supply chain for US industrial manufacturing beginswith the fuels and totals in 19,237 TBtu of primary energy input, while the onsiteenergy input results in 14,064 TBtu assuming about 27% loses offsite (Fig. 4).
Many industries generate by-products and fuels onsite, and these are also part ofthe energy supply. Notable examples are the use of black liquor and woodby-products in pulp and paper mills, syngas from petroleum refining processes,light gas mixtures that are results of chemicals processing, and blast oven gases in
4 H. Skop and Y. Chudnovsky
Fig. 3 Manufacturing energy and carbon footprint – primary energy (U.S. DOE 2014)
Fig. 4 Manufacturing energy and carbon footprint – onsite energy (U.S. DOE 2014)
Energy Efficiency and Advanced Heat Recovery Technologies 5
iron and steel mills. Renewable energy sources such as solar, geothermal, and windpower are included in other electricity generation since they are most often used toproduce electricity. Energy losses occur all along the energy supply and distributionsystem. Energy is lost in power generation and steam systems, both offsite at theutility and onsite within the plant boundary, due to equipment inefficiency andmechanical and thermal limitations. Energy is lost in distribution and transmissionsystems carrying energy both to the plant and within the plant boundary. Losses alsooccur in energy conversion systems (e.g., heat exchangers, process heaters, pumps,motors) where efficiencies are thermally or mechanically limited by materials ofconstruction and equipment design. In some cases, heat-generating processes are notlocated optimally near heat sinks, and it may be economically impractical to recoverthat excess energy. Energy is sometimes lost simply because it cannot be stored.Energy is also lost from processes when waste heat is not recovered and whenby-products with fuel value are not utilized.
It is quite difficult to distinguish between energy conversion occurring prior to theprocess and during the process as equipment is often closely integrated with theprocess unit. The top industrial energy savings opportunities for the US marketswere identified in multiple documents (e.g., U.S. DOE 2004, 2008, 2014):
• Waste heat recovery• Heat recovery from drying processes• Heat transfer enhancement• Energy source flexibility• Energy recovery from by-product gases• Heat recovery from metal quenching/cooling processes
1.2 Waste Heat Energy
Undoubtedly, among the wide spectrum of energy losses, a distinguished place isoccupied by thermal losses typically called as “waste heat” losses. Typically, wasteheat is heat, which is generated in a process by way of fuel combustion or by othermeans and then exhausted into the environment even though it could still be reusedfor some useful and economic purposes. In thermodynamics words it is the producedheat that consumer was not able to usefully employ and waste it out to the environ-ment. Often the amount of wasted heat exceeds the amount of heat left behind in theprocess. So the production cost of this amount of energy was wasted, and theenvironment was additionally polluted. Fortunately, both profits and environmentalquality can be improved by more carefully using energy. In order to minimize thedamage to the environment and to recover at least some of the costs from waste heat,we need to identify the reliable consumer of that heat and appropriate equipment forcost-effective recovery.
Industry produces waste heat in various forms that could be combined in fivemajor groups (see Fig. 5 as an example of energy Sankey diagram for the industrialheating processes):
6 H. Skop and Y. Chudnovsky
• Flue losses (typically products of the combustion processes)• Hot solids (typically heated wastes, products, and by-products)• Cooling liquids (typically cooling jackets and towers)• Cooling gases (typically air-cooling systems)• Radiation losses (typically through the insulated walls and openings)
Those waste heat sources could be easily found across the multiple industrialapplications in the operating temperature range of 100 �F to 2500 �F. So there areplenty of opportunities to the engineering community in adopting or developing thecost-effective energy-saving technologies. It should be emphasized that the essentialquality of heat is not the amount but rather its value. The strategy of how to recoverthis heat depends in part on the temperature of the waste heat gases and theeconomics involved. Table 1 below indicates the major waste heat sources.
1.3 Rules of Thumb
The most reliable way to recover energy from waste heat is to return maximal portionof the thermal energy back to the process or cycle. However, in most cases, theamount of energy recovered from waste heat is limited by parameters of mainprocess so it requires additional treatment resulted in extra costs.
Sometimes there are limitations such as unstable waste heat flow supply, pressuredrop variations, or temperature level that is much lower than the temperature neededfor certain process.
Traditionally the waste heat is recovered into the main process through thenumber of commonly accepted technologies such as recuperation and regeneration(as an example, the combustion air preheating for the gas-fired applications such asradiant U-tube as shown in Fig. 6).
Moreover, the waste heat could be successfully utilized for the secondary appli-cations such as water and space heating, absorption chilling, supplemental cogene-ration, heat supply to neighboring farms, villages, greenhouses, etc.
Wall loss
Flue losses
Opening loss
Usefuloutput
(heat to load)
Coolingwater loss
and/or conveyor
Storedheat
Availableheat
Netfuelinput
Grossfuelinput
Fig. 5 Heat losses inindustrial heating processes(U.S. DOE 2004)
Energy Efficiency and Advanced Heat Recovery Technologies 7
In the real-world practice, the engineers usually use empirically justified rules ofthumb and personal experience. For instance, 40 �F reductions in exhaust gastemperature for package boiler could increase boiler’s efficiency by approximately1%. Design engineers frequently use this approach to estimate boiler efficiency.Furthermore, the market of industrial steam generators established the exhaust gastemperature limits to which flue gases can be cooled depending on the type of fuelused: 250 �F for natural gas, 300 �F for coal and low-sulfur-content fuel oils, and350 �F for high-sulfur-content fuel oils. These limits were set to prevent condensa-tion and possible corrosion of the stack.
Table 1 Waste heat sources per operating temperature ranges
High-temperature source oC
Nickel refining furnace 1370–1650
Aluminum refining furnace 650–760
Zinc refining furnace 760–1100
Copper refining furnace 760–815
Steel heating furnaces 925–1050
Copper reverberatory furnace 900–1100
Open-hearth furnace 650–700
Cement kiln 620–730
Glass melting furnace 1000–1550
Hydrogen plants 650–1000
Solid waste incinerators 650–1000
Fume incinerators 650–1450
Coke calciner 1200–1700
Medium-temperature source oC
Steam generator exhausts 230–480
Gas turbine exhausts 370–580
Reciprocating engine exhausts 250–600
Heat treating furnaces 425–650
Drying and baking ovens 230–600
Catalytic crackers 425–650
Annealing furnace cooling systems 425–650
Thermal oxidizers 160–815
Low-temperature source oC
Process steam condensate 55–88
Cooling water 32–88
Annealing furnaces 66–230
Air compressors and pumps 27–90
Internal combustion engines 66–120
Air conditioning and refrigeration condensers 32–43
Liquid still condensers 32–88
Drying, baking and curing ovens 93–230
Hot processed liquids and solids 32–232
8 H. Skop and Y. Chudnovsky
1.4 Appropriate Equipment
The core element of any waste heat recovery system is a heat exchanger. As mentionedabove, there is no universal class of heat exchangers that could cost-effectively handlethe industrial waste heat. Why? Isn’t it enough heat transfer technologies available onthe market? Aren’t manufacturers limited in the fabrication techniques?
The quick answer is no. There are many efficient technologies and qualifiedmanufacturers available to serve the industrial market to provide the significant energysavings and efficiency improvement to industrial and large commercial end users.However, the major barrier is lack of justified strategy and reliable methodology forwaste heat recovery analysis and adequate source characterization data. It preventsmost of the original equipment manufacturers from bringing to the industrial market-place a specific class of heat exchange systems that would be acceptable for efficientand cost-effective waste heat recovery and further smart utilization. Such equipmentshould be simple in design, efficient, and reliable in operation and be as much aspossible universal for the certain application types. There are several major approachesfor the waste heat utilization on the industrial and commercial marketplace:
(a) Direct heating (i.e., drying or product preheating by the waste heat streamwithout any primary or secondary heat exchangers involved)
(b) Recuperation (i.e., combustion air preheating, heat transfer occurs via the wallwith or without special heat transfer equipment)
(c) Regeneration (i.e., the waste heat is transferred from one media to another viaregenerative packing that accumulates the heat from the hot stream and thentransfers it to cold stream)
(d) Heat recovery boiler (i.e., waste heat serves as a heat source for process steamgeneration and water heating)
(e) CHCP (combined heating, cooling, and power) generation (i.e., integratedservices under single primary mover)
Fig. 6 Typical recuperative radiant tube system for heat treating furnaces
Energy Efficiency and Advanced Heat Recovery Technologies 9
(f) Absorption chilling (i.e., waste heat conversion into cooling and refrigerationcapacity via thermal compression process)
(g) Low-temperature cycles (ORC, Kalina Cycle, Maisotsenko Cycle, HAR, etc.)
The best practices for high-temperature waste heat utilization assume the elec-tricity cogeneration by producing power steam using the hot gas as a heat input toheat recovery steam generators. Lately similar approach has been extended toward tolower level of temperature by using the low boiling temperature organic agents. Thetechnology was named as Organic Rankine Cycle (ORC). The leader in this field isOrmat Technologies Inc. that offers unique renewable power solutions based on thepatented power generation unit which converts low-, medium-, and high-temperature heat into electrical energy. Their flexible, modular solutions for geo-thermal power, recovered energy, and remote power generation are all based on theOEC (Ormat Energy Converter), which is specifically designed for customizedpower plant options. Figure 7 represents the OEC for the heat recovery from thegas turbine exhaust (Dan Nadav 2008).
Commercially available ORC systems can generate electricity from waste heatwith temperatures as low as 130 �F; however, there are still many technical andeconomic challenges in the area of low-temperature recovery.
1.5 State-of-the-Art Technologies
Nowadays many researcher engineers and technology developers focused on pro-moting a variety of the energy-saving innovations to the industrial marketplace, but
Fig. 7 OEC for heat recovery from gas turbine exhaust (Dan Nadav 2008)
10 H. Skop and Y. Chudnovsky
in some cases they are experiencing a strong resistance from the conservativeindustries. Nevertheless, industry employs a wide spectrum of waste heat recoveryequipment and techniques that are commercially available in the United States andabroad. Much of this equipment was designed for crosscutting applications and doesnot entirely utilize the waste heat stream potential. There is no standard method forclassifying this equipment, and in many cases the manufacturers offer the custom-ized designs for the specific applications. A summary of conventional or commonlyused waste heat recovery technologies for various temperature ranges is presented inTable 2 (Arvind Thekdi and Sachin Nimbalkar 2014).
The systems listed in this table are available from the manufacturers, and in mostcases, the systems are proven; however, they are continuously being improved in oneof the following areas to provide better performance and cost-effectiveness:
Table 2 A summary of waste heat recovery technologies for various temperature ranges
Ultrahightemperature(>1600 �F or870 �C)
Hightemperature(1200 �F to1600 �F or650 �C to870 �C)
Mediumtemperature(600 �F to1200 �F OR315 �C to650 �C)
Lowtemperature(250 �F to600 �F or120 �C to315 �C)
Ultralowtemperature(<250 �F or120 �C)
Refractory(ceramic)regeneratorsHeat recoveryboilersRegenerativeburnersRadiationrecuperatorWaste heatboilers includingsteam turbinegenerator-basedpower generationLoad or chargepreheating
Convectionrecuperator(metallic),mostly tubularRadiationrecuperatorRegenerativeburnersHeat recoveryboilersWaste heatboilers includingsteam turbinegenerator-basedpower generationMetallic heatwheels(regenerativesystem)Load or chargepreheating
Convectionrecuperator(metallic) ofmany differentdesignsFinned tubeheat exchanger(economizers)Shell and tubeheatexchangers forwater andliquid heatingSelf-recuperativeburnersWaste heatboilers forsteam or hotwandercondensateLoad or charge(convectionsection)preheatingHeat pipeexchangerMetallic heatwheel
Convectionrecuperator(metallic) ofmanydifferentdesignsFinned tubeheatexchanger(economizers)Shell and tubeheatexchangersfor water andliquid heatingHeat pumpsMetallic heatwheelCondensingwater heatersor heatexchangersHeat pipeexchangerDirect contactwater heaters
Shell- and tube-type heatexchangersPlate-type heatexchangersAir heaters forwaste heat fromliquidsHeat pumpsHVACapplications (i.e.,recirculationwater heating orglycol-waterrecirculation)Direct contactwater heatersNonmetallic heatexchangers
Energy Efficiency and Advanced Heat Recovery Technologies 11
– Design changes to offer higher thermal efficiency in smaller footprint or size– Cost reduction through the use of better design and manufacturing techniques– Improved seals to reduce maintenance or extend the life of the seals– Use of different materials to improve heat transfer performance ormaintenance cost– Design changes to meet customer demands for different or previously untested
applications
Many promising techniques for the low-grade and high-grade waste heat recoveryare still on the technology development market. Table 3 illustrates the emergingtechnologies that are being developed and tested at the laboratory or pilot-scale orpassed pre-commercial demonstration. The current status of the technology orproduct development depends on many factors including financial support fromthe governments, venture capitals, and/or funding agencies.
In general, the following areas are getting the most attention (Thekdi andNimbalkar 2014):
– Conversion of waste heat into a flexible and transportable energy source such aselectricity
– Heat recovery from high-temperature gases with large amounts of contaminantssuch as particulates, combustibles, and condensable vapors (organic, metallic, ornonmetallic materials)
– Heat recovery from low-temperature sources, primarily lower than 250 �F– Heat recovery from low- to medium-temperature exhaust gases or air with high
moisture content to recover the latent heat of water vapor
It should be noted that a wide spectrum of waste heat recovery analysis can befound in a variety of European works related to different industrial application. SeeOral et al. (2005) as an example of pulp and paper processing or Stehlik (2006) forwaste incineration and biomass processing.
1.6 Integrated Use of Waste Heat
As generally described above, the conventional approach for waste heat recoveryconsiders the development of the recovery system that targeted primarily to thespecific application, so it can be considered as a customized system. Such anapproach leads to the substantial cost increase of the system as well as reduces theflexibility of the equipment to any kind of future modifications.
Browsing the market of heat exchangers’ manufacturers, it is obvious that just afew heat exchangers are suitable for the waste heat recovery applications. Moreover,even these heat exchangers must be significantly adjusted in design from applicationto application.
There are following strategy principles that should be considered for the inte-grated waste heat recovery and cost-effective utilization (Skop and Chudnovsky2006):
12 H. Skop and Y. Chudnovsky
• Combined analysis of the all waste heat sources available at the selected application• Detailed consideration of the potential consumers of the waste heat in nearest
surrounding of the major source• Integration of the multiple services into one unit• Employing the advanced heat transfer and fluid flow enhancement techniques• Integrated design and engineering of the waste heat recovery system with the
original application(s)
Table 3 Emerging technologies at the development market
Ultrahightemperature(>1600 � F or870 � C)
High temperature(1200 � to 1600 �
F or 650 � to870 � C)
Mediumtemperature(600 � to 1200 �
F or 315 � to650 � C)
Lowtemperature(250 � to 600 �
F or 120 � to315 � C)
Ultralowtemperature(<250 � F or 120 �
C)
RegenerativeburnersSystems withphase changematerialAdvancedregenerativesystemsAdvancedload orchargepreheatingsystems
Recuperatorswith innovativeheat transfersurfacegeometriesThermochemicalreactionrecuperatorsAdvanced designof metallic heatwheel-typeregeneratorsAdvanced load orchargepreheatingsystemsSystems withphase changematerialSelf-recuperativeburners
Recuperatorswith innovativeheat transfersurfacegeometriesAdvanceddesign ofmetallic heatwheel-typeregeneratorsSelf-recuperativeburnersSystems withphase changematerialAdvanced heatpipe exchangerAdvanceddesign ofmetallic heatwheelThermoelectricelectricitygenerationsystems
Convectionrecuperator(metallic) ofmany differentdesignsAdvanced heatpipe exchangerAdvanced heatpumpsMembrane-type systemsfor latent heatrecovery fromwater vaporLow-temperaturepowergeneration (i.e.,ORC, Kalinacycle, etc.)Thermallyactivatedabsorptionsystems forcooling andrefrigerationSystems withphase changematerialThermoelectricelectricitygenerationsystemsCondensingwater heaters orheatexchangers
Nonmetallic(polymer orplastic) corrosion-resistant heatexchangers ofmany differentdesignsSystems withphase changematerialDesiccant systemsfor latent heatrecovery frommoisture-ladengasesMembrane-typesystems for latentheat recovery fromwater vaporCondensing waterheaters or heatexchangersThermallyactivatedabsorption systemsfor cooling andrefrigeration
Energy Efficiency and Advanced Heat Recovery Technologies 13
The abovementioned principles could be considered as a first approximation forthe development of the distinctive class of heat exchange equipment suitable for avariety of industrial waste heat recovery applications. This type of equipment issupposed to satisfy the further requirements in order to be competitive and cost-effective on the industrial market:
• Universality (or generality) in order to provide a flexibility of equipment selectionfor the specific application and simplicity of adopting the totally different appli-cations for the selected equipment
• Optimal integritywithmajor waste heat source, neighboring heat, andwaste energysources (such as acoustic, chemical, mechanical, etc.) as well as with the consumerof waste heat, energy, or derivative product (special requirements applied)
• Simplicity in design, easy in operation, and maintenance• Best practices from advanced areas (aerospace, naval, hi-tech, etc.) to be applied
along with novel materials and enhanced manufacturing technologies
Comprehensive review and analysis of the available heat transfer enhancementmethods along with a variety of designs and engineering solutions for efficient heatexchangers allow us to conclude that the most promising technologies nowadays forthe further development of the waste heat recovery systems are the following:
• Fluidized beds• Thermosyphons and heat pipes• Tubular inserts, bafflers, and swirlers• Mini- and microchannels including spiral ones• Dimpled surfaces• Silencer exchangers• System modularity and interchangeability
Employing a variety of the heat enhancement techniques in the framework ofoutlined strategy would be expected to break the industrial paradigms “the simplerthe better” and would provide developers with more efficient tools to get even betterresults.
2 Cross-References
▶Application of Fluid-Structure Interaction in Porous Media▶Boiling and Two Phase Flow in Narrow Channels▶Boiling on Enhanced Surfaces▶Compact Heat Exchangers▶Design of Optical and Radiative Properties of Surfaces▶Energy Efficiency and Advanced Heat Recovery Technologies▶Enhancement of Convective Heat Transfer▶Evaporative Heat Exchangers
14 H. Skop and Y. Chudnovsky
▶ Film and Dropwise Condensation▶ Flow Boiling in Tubes▶ Forced Convection – External Flow▶ Forced Convection – Internal Flow▶Heat Exchanger Fundamentals: Analysis and Theory of Design▶Heat Exchangers Fouling, Cleaning and Maintenance▶Heat Pipes and Thermosyphons▶Heat Transfer in Rotating Flows▶Heat Transfer Media and Their Properties▶ Internal Annular Flow-Condensation and Flow-Boiling: Context, Results, andRecommendations
▶ Introduction and Classification of Heat Transfer Equipment▶ Plasma-Particle Heat Transfer▶ Process Intensification▶ Single-Phase Heat Exchangers▶Two-Phase Heat Exchangers
References
Annual Energy Outlook 2017-2050 (2017) U.S. Energy Information Administration. https://www.eia.gov/outlooks/aeo/. Accessed 27 May 2017
Dan Nadav (2008) Recovered energy generation using ormat energy converters, presentation at theINGAA foundation Spring meeting. Accessed 27 May 2017
Energy Efficiency Market Report (2016) International Energy Agency. https://www.iea.org/eemr16/files/medium-term-energy-efficiency-2016_WEB.PDF. Accessed 27 May 2017
Energy Use, Loss and Opportunities Analysis (2004) U.S. manufacturing and mining prepared byEnergetics, Inc. and E3M, Inc. for U.S. Department of Energy Industrial Technologies Program,169pp. https://energy.gov/sites/prod/files/2013/11/f4/energy_use_loss_opportunities_analysis.pdf. Accessed 27 May 2017
Industrial Waste Heat Recovery: Potential Applications, Available Technologies and CrosscuttingR&D Opportunities by Arvind C. Thekdi and Sachin U. Nimbalkar, Oak Ridge NationalLaboratory, (2014) Report ORNL/TM-2014/622 https://info.ornl.gov/sites/publications/Files/Pub52987.pdf
Oral J, Stehlík P, Šikula J, Puchýř R, Hajný Z, Martinák P (2005) Energy utilization from industrialsludge processing in energy utilization from industrial sludge processing. Energy 30:1343–1352
Skop H, Chudnovsky Y (2006) Strategy for integrated use of the industrial waste heat, IMECE-2006-145176. In: Proceedings of the 2016 international mechanical engineering congress andexposition, Chicago, 5–10 Nov 2006
Stehlik P (2006) Key role of heat recovery in waste and biomass processing. In Proceedings of the13th international heat transfer conference, Sydney
U.S. Department of Energy, Manufacturing energy and carbon footprints (based on 2010 data with2014 assumptions). . https://energy.gov/eere/amo/manufacturing-energy-and-carbon-footprints-2010-mecs. Accessed 27 May 2017
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Energy Efficiency and Advanced Heat Recovery Technologies 15
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16 H. Skop and Y. Chudnovsky