Waste heat recovery
E-Tech manufactures economizers and other waste heat recovery products that can save your company significant money on energy. Our heat recovery economizers, boilers and heaters have been engineered and distributed to customers since Do you have a Kentube Engineered Products economizer at your facility? As the only authorized Kentube Engineered Products manufacturer, we offer replacement for Kentube Economizers. We recently acquired the assets and manufacturing equipment for Kentube Engineered Products economizers from Fintube and can engineer any size and type of Kentube economizer for your applications.
Get a quote now. The standards for a particular source category require the maximum degree of emission reduction that the EPA determines to be achievable, which is known as the Maximum Achievable Control Technology MACT . Our economizer and waste heat recovery product manufacturing processes are well within MACT standards.
E-Tech, Inc. Your Kentube Replacement Source. Economizers from E-Tech capture your wasted revenue — and may be eligible for some government grants and rebates. The Economizer and Heat Recovery Experts.Revision This is a preview of the paper, limited to some initial content.
Full access requires DieselNet subscription. Please log in to view the complete version of this paper. Waste heat recovery WHR is the use of thermal energy that would otherwise be transferred to the environment to accomplish a useful function. In many cases, WHR avoids or reduces the need for additional fuel energy input that would be otherwise required to achieve this function. Examples for internal combustion engines include:.
The main pathways for heat rejection in the internal combustion engine that are potential candidates for WHR include the hot exhaust gases discharged from the tailpipe, the engine coolant radiator, as well as the EGR and charge air coolers. In many cases, the goal of WHR is to generate additional work. Higher quality heat sources allow a larger portion of the waste heat to be converted to work. The higher the temperature of the medium, the higher its entropy, which allows a larger portion of the heat to be converted to useful work i.
For instance, a WHR system driven by heat from the EGR cooler in a high pressure EGR loop can be expected to have a higher efficiency than a similar system that recovers heat from the tailpipe exhaust gases.
Waste heat from a heat engine or power plant is rejected to the environment either through a heat exchanger or directly through the expulsion of the hot working fluid.
Figure 1 summarizes the main pathways for heat rejection in a heavy-duty diesel engine that are potential candidates for waste heat recovery .
Waste Heat Recovery Resource Page
The usefulness of these heat sources for the purpose of WHR depends on:. Figure 2 illustrates in more detail the temperature of various heat rejection streams shown in Figure 1 for a heavy-duty diesel engine as a function of engine power.
Engine: EPA emissions. Figure 3 illustrates the proportion of fuel energy producing brake work and lost through the various waste heat streams for three power settings of the engine of Figure 2. Also shown are more details of the waste streams that are available for WHR including the proportion of exhaust heat remaining in the exhaust gas after the aftertreatment system and the amount of heat transferred from the EGR cooler to the engine coolant .
Table 1 summarizes the energy and a first approximation of the exergy—based on the Carnot factor—of the different waste heat sources for two of the operating conditions of Figure 3 exergy represents the amount of work that can be theoretically produced from an energy flow.
Waste heat from the EGR cooler represents the highest temperature heat available and therefore a high priority for WHR.Discover how today. Thank you for your interest in GE. A representative from our team will contact you within business days. See step-by-step how our waste heat exchanger integrates with your existing equipment to save on operating costs. For more details on this process and how it can help you recover valuable energy, please contact GE power today.
To combat the price of iron and steel, we want to help you lower your operating expenses. Have questions for GE? Thank you Thank you for your interest in GE. Hot flue gas from the furnace is routed through the heat exchanger HEX and cooled in a controlled way Through this controlled flue gas cooling, dioxin formations are eliminated Energy is transferred from flue gas to water The recovered flue gas water is routed to existing boiler feedwater preheater or district heating applications Dust accumulation is prevented by a proprietary cleaning mechanism that continuously removes dust from tubes, preventing build-up The quenching tower cools flue gas quickly to minimize the release of harmful gases.
With HEX technology, the use of a quench tower can be reduced, minimizing both maintenance time and costs The cooled flue gas is routed to de-dusting equipment. Other details include: The melting energy used in the installation amounted to 70 MWel Recovering heat from the smelting exhaust produces 20 MWel. Contact GE to start recovering wasted energy.Waste heat recovery is the collection of heat created as an undesired by-product of the operation of a piece of equipment or machinery to fill a desired purpose elsewhere.
Waste heat recouping methods range from the simple to the complex. A common simple example is household water drain heat recovery.
In this method, the heat going down a sink or shower drain is recovered by a copper pipe coiling around the drain pipe. The coil is then used to heat water as it passes through pipes on the way to a hot water heater. On the more complex side, heat recovered from liquid cooling systems in data centers can be used for parts of the facilities where warmer temperatures are desired. Other sources of waste heat that can be recovered for practical uses include car exhaust, industrial exhaust, thermoelectric generation and turbines.
Depending on the application, the heat itself may be the desired product or may be subjected to another process to provide clean electricity. According to the United States Department of Energy, up to 50 percent of the energy from all fuels burned in the U. See also: thermoelectric coolingpower usage effectiveness PUEcarbon usage effectiveness CUEgreenhouse effectrenewable resourcenon-renewable resource.
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This was last updated in November Related Terms disaster recovery DR Disaster recovery DR is an area of security planning that aims to protect an organization from the effects of significant Login Forgot your password? Forgot your password? No problem! Submit your e-mail address below. We'll send you an email containing your password. Your password has been sent to:.As the industrial sector continues efforts to improve its energy efficiency, recovering waste heat losses generate cost savings, reduces environmental impact, and improves work flow and productivity.
Waste heat recovery from process heating systems. The guide covers: steam system profiling; identification of steam properties; boiler operations improvements; improvement of steam system utilization; and the determination of steam distribution system energy losses. AMO has carried out a good amount of work with CHP systems that involve bottom up waste heat recovery conversion to power.
Waste Heat to Power Market Assessment. Estimates suggest the system would generate net income in three years and provide national energy savings of 0. Heat exchangers manufactured from polymer composites would have several advantages over metal heat exchangers, including lower weight, improved corrosion resistance, and compared to the current manufacture of metal heat exchangers, increased energy productivity and lower greenhouse gas emissions.
Skip to main content. Tools and related resources - Process Heating Assessment Software Tool PHAST identifies WHR upgrade opportunities from process heating equipment such as furnaces, ovens, kilns, dryers and boilers in the areas of wall heat losses, heat storage and stack heat recovery.By recovering waste heat, plants can reduce energy costs and CO 2 emissions, while simultaneously increasing energy efficiency.
Several common consumer items recover waste heat. For example, consider turbocharged cars, which are provided by multiple car manufacturers. That gas contains both heat and kinetic energy—a portion of which can be recovered. Turbocharged engines divert the hot gas to a turbine, which is used to spin an air compressor.
The energy benefits of industrial waste heat recovery can be similar, and some examples are examined in this article.
Stack economizers, commonly used to heat water, are among the simplest type of waste heat recovery. Plant workers may be familiar with these common devices that recover waste heat. Boiler stack economizers use heat energy from the gas expelled in the heating process into the stack to heat boiler feed water and reduce the amount of energy required to make steam.
Using a principle similar to economizers, waste heat boilers recover heat generated in furnaces or exothermic chemical reactions at industrial plants.
These locations may contain significant energy that should not be wasted up a stack. Instead, this energy can be captured to generate low-to-medium pressure steam in a waste heat boiler WHB. A WHB can also be used to remove the heat from a process fluid that needs to be cooled for either transport or storage, and generate steam from that heat. The steam generated in WHB may be used for heating applications, or to drive turbines that generate electricity, compress vapors, or pump liquids.
WHB steam may contain significant wetness, so it is recommended that a high efficiency separator and steam trap combination is installed to ensure that the WHB delivers optimal quality steam to the recipient process.
Many highly efficient industrial plants with cogeneration or combined cycle systems use a gas-turbine essentially a jet engine to generate electricity then create steam from the waste heat using a heat recovery steam generator HRSG. This section will explain how this process works and how an HRSG comes into action. Consider the previous example of a turbocharged car engine, but instead change the motor to a jet engine. So, how can that waste heat be used as was done with the turbocharged auto?
The expelled hot gas needs to drive another turbine, so the exhaust is passed through a HRSG, which creates superheated steam that drives a downstream steam-turbine. The turbine can either drive a generator combined cycle system or just use the steam in process applications cogeneration or combined heat and power CHP. HRSGs can have either a single steam drum as shown in the animation below or multiple steam drums and pressures. There are also both unfired varieties with natural circulation shown below and varieties with duct firing, which is additional heating.
Duct firing increases steam generation and quality, and has the ability to create superheated steam and even greater power at a turbine.
Some energy efficient CHP systems may add refrigeration by incorporating absorption chillers that use steam created from waste heat. Thermocompression is another heat recovery approach that can utilize the energy in an otherwise wasted stream, such as low-pressure steam.
Wherever flash steam occurs, the possibility of its use as a low-pressure steam source should be considered.
Low-pressure steam can be used to make hot water for process or domestic use. If the supply of steam from a waste heat source is not continuous, the supplied steam can be kept constant by using a supplemental steam valve.
There are often many opportunities for heat recovery in steam systems, including some which may not be included in this article. Products Browse Products by Category. Find a Specific Model. Technical Documents. Product Solutions.
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Steam Theory. Engineering Calculator.With the high cost and environmental impact of fossil fuels, heat energy is a precious commodity that cannot be wasted. Consumers of waste heat energy can be found in almost any facility and are easy to locate. Typical examples include plant process heating, combustion air pre-heating, boiler feedwater pre-heating, and building heat.
In addition to savings in everyday fuel consumption, many facilities can market and sell carbon credits back to industry. Sigma Thermal engineers are heat energy management experts. If the audit results in recommendations for heat recovery equipment, we can provide that equipment and guarantee the energy savings, ensuring that your recovery potential is fully realized. With experience in a broad range of transfer fluids, we can show you your options and design a system that best fits your needs.
Sigma Thermal offers complete closed loop, liquid phase, waste heat recovery systems utilizing water, glycol solutions and thermal oils.
An E-Tech Economizer Can Keep Your Energy Dollars from Vaporizing Into Thin Air.
A combustion air pre-heat system increases overall system efficiency and minimizes system operating costs. Heater exhaust gasses are utilized to pre-heat the incoming combustion air.
This is a more efficient utilization of the energy consumed, which results in lower natural gas operating costs. A typical summary of combustion air pre-heat system components is as follows:. Sigma Thermal specializes in biomass combustion and gasification systems, and has extensive design experience in capturing waste heat from high particulate exhaust gas.
Once energy has been recovered from high particulate exhaust gas, it can be utilized with any traditional waste heat consumer. As the potash mining industry continues to grow and change, Sigma Thermal will keep offering innovative solutions with ongoing system design improvements. In this This site uses functional cookies and external scripts to improve your experience. Which cookies and scripts are used and how they impact your visit is specified on the left. You may change your settings at any time.
Your choices will not impact your visit. NOTE: These settings will only apply to the browser and device you are currently using. Waste Heat Recovery With the high cost and environmental impact of fossil fuels, heat energy is a precious commodity that cannot be wasted.
A typical summary of combustion air pre-heat system components is as follows: Air to air heat exchanger Modified burner to accommodate elevated combustion air temperatures Combustion air ductwork from combustion fan to heat exchanger and from heat exchanger to heater Exhaust gas ductwork from heater to heat exchanger, and from heat exchanger to stack if applicable.
High Particulate Systems Sigma Thermal specializes in biomass combustion and gasification systems, and has extensive design experience in capturing waste heat from high particulate exhaust gas.