55 Waste heat

This Method Quickly Determines Required Heat Transfer Surface Area and How Changing Loads Will Affect Performance 

Example 1. A waste heat boiler is to be designed to cool 75,000 Ib/h of flue gases from 1,625°F to 535°F, generating steam at 70psia. Tubes of size 2-in. OD and 1.8-in. ID are to be used. Estimate the surface area and 

Example 2. What is the duty and exit gas temperature in the boiler if 60,000 Ib/h of flue gases enter the boiler at 1,200°F Steam pressure is the same as in example 1. 

A = Surface area ft based on tube ID C = Gas specific heat. Btu/lb°F d = Tube inner diameter, in. k = Gas thermal conductivity, Btu/ft-h°F L = Tube length, ft N = Total number of tubes in boiler Pr = Gas Prandtl number Q = Duty of the boiler. Btu/h 

U = Overall heat transfer coefficient, Btu/ft h°F (based on tube ID) p = Gas viscosity, Ib/ft-h 

All thermal power plants produce waste heat energy as a by-product of the useful electrical energy produced. The amount of waste heat energy equals or exceeds the amount of electrical 

In areas with restricted water use, a dry cooling tower or radiator, directly air cooled, may be necessary, since the cost or environmental consequences of obtaining makeup water for evaporative cooling would be prohibitive. These have lower efficiency and higher-energy consumption in fans than a wet, evaporative cooling tower. 

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The policy for waste heat recovery from the flue gas varies between incinerator operators. Incinerators located on the waste producer s site tend to be fitted with waste heat recovery systems, usually steam generation, which is fed into the site steam mains. Merchant incinerator operators, who incinerate other people s waste and... 

The inability to produce high-quality effluents is one significant disadvantage. Another disadvantage is that anaerobic processes must be maintained at temperatures between 35 and 40°C to get the best performance. If low-temperature waste heat is available from the production process, then this is not a problem. 

Waste activated sludge Waste biomass Waste-derived fuels Waste disposal Waste-heat boiler... 

Incineration. Gases sufftciendy concentrated to support combustion are burned in waste-heat boilers, dares, or used for fuel. Typical pollutants treated by incineration are hydrocarbons, other organic solvents and blowdown gases, H2S, HCN, CO, H2, NH, and mercaptans. VOC... 

Some beehive ovens, having various improvements and additions of waste heat boilers, thereby allowing heat recovery from the combustion products, may stiU be in operation. Generally, however, the beehive oven has been replaced by waH-heated, horizontal chamber, ie, slot, ovens in which higher temperatures can be achieved as well as a better control over the quality of the coke. Modem slot-type coke ovens are approximately 15 m long, approximately 6 m high, and the width is chosen to suit the carbonization behavior of the coal to be processed. For example, the most common widths are ca 0.5 m, but some ovens may be as narrow as 0.3 m, or as wide as 0.6 m. 

The gas, along with entrained ash and char particles, which are subjected to further gasification in the large space above the fluid bed, exit the gasifier at 954—1010°C. The hot gas is passed through a waste-heat boiler to recover the sensible heat, and then through a dry cyclone. SoHd particles are removed in both units. The gas is further cooled and cleaned by wet scmbbing, and if required, an electrostatic precipitator is included in the gas-treatment stream. 

The hot gases from the combustor, temperature controlled to 980°C by excess air, are expanded through the gas turbine, driving the air compressor and generating electricity. Sensible heat in the gas turbine exhaust is recovered in a waste heat boiler by generating steam for additional electrical power production. 

Pkctro-Keforming The concept of using electricity to provide the endothermic heat of reforming has been proposed. Nuclear waste heat can be contained in high temperature helium gas which is brought into heat exchange with a natural gas feedstock (142). 

The final composition of the reactor product gas is estabUshed by the water gas shift equiUbrium at the reactor outiet waste-heat exchanger inlet where rapid cooling begins. Some units quench instead of going directiy to heat exchanger. 

Equipment. Partial-oxidation gasification section equipment in many plants consists essentially of (/) the gasification reactor (2) the waste-heat exchanger for heat recovery from the hot reactor gas or direct quench system (J) the economizer heat exchanger for further heat recovery (4) the carbon removal system for separating carbon from the reactor product gas and (5) the carbon recovery system for recycle of carbon. 

The latest installations incorporate a waste heat boiler in the off-gas cleaning system to recover sensible heat from the rotary kiln off-gas. There is sufficient sensible heat in the off-gas from the SL/RN process to generate 500 to 700 kWh/t of DRJ, depending on the type of reductant used. 

Reducing gas is generated from natural gas in a conventional steam reformer. The natural gas is preheated, desulfurized, mixed with steam, further heated, and reformed in catalyst-filled reformer tubes at 760°C. The reformed gas is cooled to 350°C in a waste heat boiler, passed through a shift converter to increase the content, mixed with clean recycled top gas, heated to 830°C in an indirect-fired heater, then injected into reactor 4. 

The combined flue dust from waste heat boiler and electrostatic precipitator, including dust from the ventilation system, is collected in a bin and recirculated to the mixing and pelletizing step, where it is used as a binding reagent. 

Owing to the cycHc nature of the TBRC operation, waste heat recovery from the off-gases is not practical and the SO2 content of the gas varies with the converter cycle. In order to supply a relatively uniform flow and strength SO2 gas to a sulfuric acid plant, a system has been installed at RonnskAr whereby the SO2 from fluctuating smelter gases is partially absorbed in water. During smelter gas intermption, SO2 is stripped with air and the concentrated gas deflvered to the acid plant. 

Noncatalytic partial oxidation of residual fuel oil accounts for the remainder of world methanol production. Shell and Texaco ate the predominant hcensors for partial oxidation technology (16) the two differ principally in the mechanical details of mixing the feedstock and oxidant, in waste heat recovery, and in soHds management. 

Many units have waste heat recovery systems that generate low pressure steam from reaction heat. Such steam is often employed to drive adsorption refrigeration units to cool the reactor feed stream and to increase polymer conversion per pass, an energy-saving process that reduces the demand for electrical power. 

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