Industrial Waste Heat Recovery

Industrial Waste Heat Recovery
Industrial Energy RoundTable
Kathey Ferland
Project Manager
Texas Industries of the Future
kferland@mail.utexas.edu
Riyaz Papar, PE, CEM

Director, Energy Assets & Optimization
Hudson Technologies Company
rpapar@hudsontech.com
September 21, 2006

© Hudson Technologies
Welcome & Introductions
Sponsor
US Department of Energy Office
of Energy Efficiency and
Renewable Energy, under a
contract with the State Energy
Conservation Office
Agenda
Welcome and Introductions
Industrial Waste Heat Recovery Presentation

¾ Concepts & questions
¾ Some ideas and technology examples
9 Sensible preheating
9 Condensing economizers
9 Fumes to fuel / Power generation
9 Mechanical vapor recompression or Thermal compression
9 Industrial heat pumps
9 Chilled water / Refrigeration
¾ Challenges
Round table discussion

DOE Technology RoadMap
www.eere.energy.gov/industry/energy_systems/pdfs/reduction_roadmap.pdf
Concepts & Questions
What is waste heat recovery?

¾ Industry dependent
9 Glass, metals industry - 750°F
9 PetroChemicals & refining - 300°F
9 Food & beverage industry - 180°F
9 Buildings and facilities - 140°F
How much is it?

¾ Heat content – MMBtuh
¾ Product yield
What is it (substance)?
¾ Contaminated waste steam from fractionating / stripping process
¾ Waste gases from boilers, furnaces, vents, flares, etc.
Can it be recovered?
Can it be used?
Where is it?
¾ Utility plant
¾ Process unit
What is the environment?

¾ Sensible
¾ Latent
¾ Acidic, etc.
¾ Direct / Indirect contact
When is it available?
¾ Continuous
¾ Batch mode
Ideas & Technologies
Sensible preheating
Condensing economizers
Fumes to fuel / Power generation
Mechanical vapor recompression or Thermal compression
Industrial heat pumps
Chilled water / Refrigeration
Other ideas from the RoundTable group…..
Sensible Preheating
Most common form found in the industry
Utility side
¾ BFW preheat
¾ Blowdown / Makeup heat recovery
¾ Combustion air preheat
¾ Compressed air heat recovery
¾ Other…..
Process side – typically some level of pinch or optimization

is done and so the process is highly integrated
¾ Preheat reaction feed streams
¾ Preheat process water
¾ Other…..
Condensing Economizers
Very predominant in Europe
Relatively recent in the US – less than 5 years in market –

but it has picked up now
Two types
¾ Direct contact
¾ Closed loop
Industrial applications are seeing simple paybacks: 6 months

- 2 years
Several installations, manufacturers, gas companies
SuperBoiler?
100 25
Not a bigger boiler
Footprint, sq ft per klb/h steam

80 20
but a better boiler!
Energy Efficiency, %
Higher energy efficiency -
NOx, ppmv
¾ 60 15
more than 95% HHV
¾ Super-low emissions - 40 10
down to 2 ppm NOx
and 5 ppm CO
20 5
¾ Smaller and lighter -
reduce size and weight by
50 percent 0 0
Typical State of the 2020 Super
¾ Competitive performance industrial art* Boiler
¾ Cost-effective boiler
Efficiency Emissions Footprint
* Not all in the same boiler
1st Generation SuperBoiler
Project Description:
Gas-fired firetube boiler using
innovative concepts in burner, heat
transfer, heat recovery & control
Partnered with Cleaver-Brooks
Technical Objectives
¾ 94% efficiency (from 70-83%)
¾ <5 ppm NOx (from 30-100 ppm)
¾ Two sites selected

9 Alabama Rubber Plant
Boiler up and in operation
9 California Fruit Processing Plant

Boiler being built
Fumes to Fuel Technology
Ford Motor Company & DTE Energy Partnership

VOC concentrator – applicable to chemical plants
Solid Oxide Fuel Cell
MVR / Thermal Compression
Main intent – Recover latent energy of low pressure

steam
Mechanical Vapor Recompression
¾ Boost the vented steam pressure via an electric motor
driven compressor
¾ Based on compression ratio, energy used by compressor
could be only 10-15% of boiler energy
Thermal Compression
¾ Use of a converging-diverging nozzle
¾ Needs motive steam
¾ Called an Ejector when used to create vacuum
Industrial Heat Pumps
http://www1.eere.energy.gov/industry/bestpractices/pdfs/heatpump.pdf
Industrial Heat Pumps
Heat Amplifier
¾ Will need
9 Motive heat (high temperature)
9 Waste heat
¾ Will provide
9 Medium temperature heat
9 Amount of heat provided will be sum of waste heat &
motive heat
Temperature Amplifier
¾ Will need
9 Waste heat
9 Ambient temperature heat rejection
¾ Will provide
9 High temperature heat
9 Amount of heat provided will be difference between waste
heat & heat rejected to ambient
Waste Heat fired Absorption Chillers
Commercially available – LiBr/water machines

Provide chilled water only
Can use waste heat, low pressure steam
http://www.ornl.gov/sci/engineering_science_technology/cooling_heating_power/pdf/ISHPC-095-2005.pdf
Refrigeration From Engine Waste Heat
Courtesy: Energy Concepts Company
160 tons refrigeration at 25F

waste heat from 830 kW gas-fired reciprocating engine
uses both exhaust heat and jacket heat
8 ft by 8 ft footprint, 9000 pounds
Waste Heat Refrigeration
Installed in 1997
Recovers 200 barrels LPG per day
Double lift cycle, -25oF from 280oF liquid
stream
Courtesy: Energy Concepts Company

Ammonia Absorption Refrigeration
At comparable production levels, cost approximates vapor

compression $/ton
Custom units start at $1000 per ton
Subzero temperature industrial systems show cost advantage

over mechanical vapor compression
Ammonia absorption is built to industrial standards. This

means that AA can be directly integrated into the process,
which makes a lot more things possible.
More attractive paybacks (1 to 3 years) are obtained with

debottleneck applications and increased recovery applications.
Adsorption Chiller
HIJC USA, INC.
Adsorption Chiller
HIJC USA, INC.
Challenges
Diverse industrial processes and site specific conditions
Energy price and supply uncertainties
Regulatory uncertainties
Materials durability – Metallurgy
Equipment fouling
Reliability
Safety
Economic feasibility
Other Comments
Mechanical vapor recompression and thermal

recompression to reuse the waste heat in
distillation overhead as a heat source for reboiling
Useful applications for waste steam at low

pressures, less than 20 psig
Understand where recovery of low level heat has

proven cost effective
RoundTable Discussion

Industrial Waste Heat Recovery

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Industrial Waste Heat Recovery

Industrial Energy RoundTable

Riyaz Papar, PE, CEM

September 21, 2006

 Welcome and Introductions

 Industrial Waste Heat Recovery Presentation

 Round table discussion

 What is waste heat recovery?

 How much is it?

 What is the environment?

 Fumes to fuel / Power generation

 Mechanical vapor recompression or Thermal compression

 Industrial heat pumps

 Chilled water / Refrigeration

 Other ideas from the RoundTable group…..

 Most common form found in the industry

 Process side – typically some level of pinch or optimization

 Very predominant in Europe

 Relatively recent in the US – less than 5 years in market –

 Industrial applications are seeing simple paybacks: 6 months

 Several installations, manufacturers, gas companies

Not a bigger boiler

Footprint, sq ft per klb/h steam

Efficiency Emissions Footprint

* Not all in the same boiler

¾ Two sites selected

9 California Fruit Processing Plant

 Ford Motor Company & DTE Energy Partnership

 Main intent – Recover latent energy of low pressure

 Commercially available – LiBr/water machines

Courtesy: Energy Concepts Company

 160 tons refrigeration at 25F

Courtesy: Energy Concepts Company

 At comparable production levels, cost approximates vapor

 Custom units start at $1000 per ton

 Subzero temperature industrial systems show cost advantage

 Ammonia absorption is built to industrial standards. This

 More attractive paybacks (1 to 3 years) are obtained with

HIJC USA, INC.

HIJC USA, INC.

 Diverse industrial processes and site specific conditions

 Energy price and supply uncertainties

 Materials durability – Metallurgy

 Mechanical vapor recompression and thermal

 Useful applications for waste steam at low

 Understand where recovery of low level heat has

Anda mungkin juga menyukai

Welcome and Introductions

Industrial Waste Heat Recovery Presentation

Round table discussion

What is waste heat recovery?

How much is it?

What is the environment?

Fumes to fuel / Power generation

Mechanical vapor recompression or Thermal compression

Industrial heat pumps

Chilled water / Refrigeration

Other ideas from the RoundTable group…..

Most common form found in the industry

Process side – typically some level of pinch or optimization

Very predominant in Europe

Relatively recent in the US – less than 5 years in market –

Industrial applications are seeing simple paybacks: 6 months

Several installations, manufacturers, gas companies

Ford Motor Company & DTE Energy Partnership

Main intent – Recover latent energy of low pressure

Commercially available – LiBr/water machines

160 tons refrigeration at 25F

At comparable production levels, cost approximates vapor

Custom units start at $1000 per ton

Subzero temperature industrial systems show cost advantage

Ammonia absorption is built to industrial standards. This

More attractive paybacks (1 to 3 years) are obtained with

Diverse industrial processes and site specific conditions

Energy price and supply uncertainties

Materials durability – Metallurgy

Mechanical vapor recompression and thermal

Useful applications for waste steam at low

Understand where recovery of low level heat has