Heat Recovery System

• waste heat recovery unit (WHRU) is an energy recovery heat exchanger that recovers
heat from hot streams with potential high energy content, such as hot flue gases from a
diesel generator or steam from cooling towers or even waste water from different
cooling processes such as in steel cooling, according to a report done by Energetic
Incorporated for the DOE in November 2004 titled Technology Roadmap and several
others done by the European commission, the majority of energy production from
conventional and renewable resources are lost to the atmosphere due to onsite
(equipment inefficiency and losses due to waste heat) and offsite (cable and
transformers losses) losses, that sums to be around 66% loss in electricity value. Waste
heat of different degrees could be found in final products of a certain process or as a
by-product in industry such as the slag in steelmaking plants. Units or devices that could
recover the waste heat and transform it into electricity are called WHRUs or heat to
power units. For example, an Organic Rankine cycle unit uses an organic fluid as the
working fluid. The fluid has a lower boiling point than water to allow it to boil at low
temperature, to form a superheated gas that could drive the blade of a turbine and thus
a generator. Thermoelectric (Seebeck, Peltier, Thomson effects) units may also be
called WHRU, since they use the heat differential between two plates to produce DC
Power. Shape-memory alloys can also be used to recover low temperature waste heat
and convert it to mechanical action or electricity. A WHRB is different from a Heat
Recovery Steam Generator (HRSG) in the sense that the heated medium does not
change phase. Waste Heat Recovery from various Processes in Industries is achieved
by efficient utilization of available energy resources. Various mechanical equipments
are specially designed for trapping Waste Heat from a certain process, thereby
increasing its efficiency. e.g.- Regenerators, Economizer, Plate Heat exchanger, Heat
pump etc.

Equipments for waste heat recovery system

Economiser- These are mechanical devices intended to reduce energy consumption, or to

perform useful function such as preheating a fluid. The term economizer is used for other
purposes as well. Boiler, power plant, heating, Refrigeration, ventilating, and air conditioning
(HVAC) uses are discussed in this article. In simple terms, an economizer is a heat exchanger.
Modern-day boilers, such as those in coal-fired power stations, are still fitted with economizers
which are descendants of Green's original design. In this context they are often referred to as
feed water heaters and heat the condensate from turbines before it is pumped to the boilers.

Economizers are commonly used as part of a heat recovery steam generator in a combined
cycle power plant. In an HRSG, water passes through an economizer, then a boiler and then a
superheater. The economizer also prevents flooding of the boiler with liquid water that is too
cold to be boiled given the flow rates and design of the boiler.

A common application of economizers in steam power plants is to capture the waste heat from
boiler stack gases (flue gas) and transfer it to the boiler feed water. This raises the temperature
of the boiler feed water, lowering the needed energy input, in turn reducing the firing rates
needed for the rated boiler output. Economizers lower stack temperatures which may cause
condensation of acidic combustion gases and serious equipment corrosion damage if care is
not taken in their design and material selection.
 Economiser
Metallic radiation recuperators- This is a special purpose counter-flow energy recovery heat
exchanger positioned within the supply and exhaust air streams of an air handling system, or
in the exhaust gases of an industrial process, in order to recover the waste heat. Normally the
heat transfer between airstreams provided by the device is termed as "sensible heat", which is
the exchange of energy, or enthalpy, resulting in a change in temperature of the medium (air in
this case), but with no change in moisture content. However, if moisture or relative humidity
levels in the return air stream are high enough to allow condensation to take place in the device,
then this will cause "latent heat" to be released and the heat transfer material will be covered
with a film of water. Despite a corresponding absorption of latent heat, as some of the water
film is evaporated in the opposite airstream, the water will reduce the thermal resistance of the
boundary layer of the heat exchanger material and thus improve the heat transfer coefficient of
the device, and hence increase efficiency. The energy exchange of such devices now comprises
both sensible and latent heat transfer; in addition to a change in temperature, there is also a
change in moisture content of the exhaust air stream.

However, the film of condensation will also slightly increase pressure drop through the device,
and depending upon the spacing of the matrix material, this can increase resistance by up to
30%. If the unit is not laid to falls, and the condensate not allowed to drain properly, this will
increase fan energy consumption and reduce the seasonal efficiency of the device.
 Metallic radiation recuperators

Plate Heat exchanger- It is a type of heat exchanger that uses metal plates to transfer heat
between two fluids. This has a major advantage over a conventional heat exchanger in that the
fluids are exposed to a much larger surface area because the fluids spread out over the plates.
This facilitates the transfer of heat, and greatly increases the speed of the temperature change.
Plate heat exchangers are now common and very small brazed versions are used in the hot-
water sections of millions of combination boilers. The high heat transfer efficiency for such a
small physical size has increased the domestic hot water (DHW) flow rate of combination
boilers. The small plate heat exchanger has made a great impact in domestic heating and hot-
water. Larger commercial versions use gaskets between the plates, whereas smaller versions
tend to be brazed.

The concept behind a heat exchanger is the use of pipes or other containment vessels to heat or
cool one fluid by transferring heat between it and another fluid. In most cases, the exchanger
consists of a coiled pipe containing one fluid that passes through a chamber containing another
fluid. The walls of the pipe are usually made of metal, or another substance with a high thermal
conductivity, to facilitate the interchange, whereas the outer casing of the larger chamber is
made of a plastic or coated with thermal insulation, to discourage heat from escaping from the
exchanger.

The plate heat exchanger (PHE) was invented by Dr Richard Seligman in 1923 and
revolutionised methods of indirect heating and cooling of fluids. Dr Richard Seligman founded
APV in 1910 as the Aluminium Plant & Vessel Company Limited, a specialist fabricating firm
supplying welded vessels to the brewery and vegetable oil trades. The plate heat exchanger
(PHE) is a specialized design well suited to transferring heat between medium- and low-
pressure fluids. Welded, semi-welded and brazed heat exchangers are used for heat exchange
between high-pressure fluids or where a more compact product is required. In place of a pipe
passing through a chamber, there are instead two alternating chambers, usually thin in depth,
separated at their largest surface by a corrugated metal plate. The plates used in a plate and
frame heat exchanger are obtained by one piece pressing of metal plates. Stainless steel is a
commonly used metal for the plates because of its ability to withstand high temperatures, its
strength, and its corrosion resistance.

The plates are often spaced by rubber sealing gaskets which are cemented into a section around
the edge of the plates. The plates are pressed to form troughs at right angles to the direction of
flow of the liquid which runs through the channels in the heat exchanger. These troughs are
arranged so that they interlink with the other plates which forms the channel with gaps of 1.3–
1.5 mm between the plates. The plates are compressed together in a rigid frame to form an
arrangement of parallel flow channels with alternating hot and cold fluids. The plates produce
an extremely large surface area, which allows for the fastest possible transfer. Making each
chamber thin ensures that the majority of the volume of the liquid contacts the plate, again
aiding exchange. The troughs also create and maintain a turbulent flow in the liquid to
maximize heat transfer in the exchanger. A high degree of turbulence can be obtained at low
flow rates and high heat transfer coefficient can then be achieved.

As compared to shell and tube heat exchangers, the temperature approach in a plate heat
exchangers may be as low as 1 °C whereas shell and tube heat exchangers require an approach
of 5 °C or more. For the same amount of heat exchanged, the size of the plate heat exchanger
is smaller, because of the large heat transfer area afforded by the plates (the large area through
which heat can travel). Increase and reduction of the heat transfer area is simple in a plate heat-
exchanger, through the addition or removal of plates from the stack.

Plate Heat Exchanger

 Lagging-Lagging means insulation which is used to prevent heat diffusion as from the steam
pipe, furnace, exchangers etc. All furnace are highly insulated in multiple layers to minimize
the heat looses and to maintain a high temperature inside the furnace. Electrical wires are
always kept insulated ( poly vinyl chloride used as a insulator) and this layer of insulation
also act as thermal insulator. A special material that is used to cover something to keep it
from losing or gaining heat.

Types of lagging materials

Wood fibre- Wood fibre are usually cellulosic elements that are extracted from trees
and used to make materials including paper. The end paper product (paper, paperboard,
tissue, cardboard, etc.) dictates the species, that is best suited to provide the desirable
sheet characteristics, and also dictates the required fibre processing (chemical
treatment, heat treatment, mechanical "brushing" or refining, etc.)

Wood fiber
Cellulose- An insulation is a material made from recycled newspaper. The paper is
shredded and inorganic salts, such as boric acid, are added for resistance to fire, mould,
insects and vermin. The insulation is installed either blown or damp-sprayed.

Cellulose
Wool- insulation is made from sheep wool fibres that are either mechanically held together
or bonded using between 5% and 15% recycled polyester adhesive to form insulating batts and
rolls. Sheep are no longer farmed primarily for their wool; however, they need to be clipped
annually to protect the health of the animal. The wool used to manufacture insulation is the
wool discarded as waste by other industries due to its colour or grade.

Wool

Hemp -fibres are produced from hemp straw of the hemp plant. Most hemp is imported, but
an increasing amount of home-grown crop is becoming available. Hemp grows up to a height
of nearly 4 metres within a period of 100-120 days. Because the plants shade the soil, no
chemical protection or toxic additives are required for hemp cultivation. The product is
composed of, usually, 85% hemp fibre with the ballance made up of polyester binding and 3-
5% soda added for fire proofing.

Hemp
Glass mineral wool – is made from molten glass, usually with 20% to 30% recycled industrial
waste and post-consumer content. The material is formed from fibres of glass arranged using a
binder into a texture similar to wool. The process traps many small pockets of air between the
glass, and these small air pockets result in high thermal insulation properties. The density of
the material can be varied through pressure and binder content.

Glass mineral wool

Polyurethane- (PUR and PU) is a polymer composed of organic units joined

by carbamate (urethane) links. Polyurethane can be made in a variety of densities and
hardnesses by varying the isocyanate, polyol or additives.

Polyurethane