Roundtable 0906

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Hudson TechnologiesHudson Technologies

Industrial Waste Heat RecoveryIndustrial Waste Heat Recovery

Industrial EnergyIndustrial Energy RoundTableRoundTable

Kathey Ferland

Project ManagerTexas Industries of the Future

[email protected]

Riyaz Papar, PE, CEMDirector, Energy Assets & Optimization

Hudson Technologies Company

[email protected]

September 21, 2006


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Welcome & Introductions

SponsorUS Department of Energy Officeof Energy Efficiency andRenewable Energy, under a

contract with the State EnergyConservation Office


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Agenda

Welcome and Introductions

Industrial Waste Heat Recovery Presentation Concepts & questions

Some ideas and technology examples

Sensible preheating

Condensing economizers

Fumes to fuel / Power generation

Mechanical vapor recompression or Thermal compression

Industrial heat pumps

Chilled water / Refrigeration

Challenges

Round table discussion


4/29 Hudson TechnologiesHudson Technologies

DOE Technology RoadMap

www.eere.energy.gov/industry/energy_systems/pdfs/reduction_roadmap.pdf



Concepts & Questions


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What is waste heat recovery? Industry dependent

Glass, metals industry - 750F

PetroChemicals & refining - 300F

Food & beverage industry - 180F

Buildings and facilities - 140F

How much is it?

Heat content MMBtuh Product yield

What is it (substance)?

Contaminated waste steam from fractionating / stripping process Waste gases from boilers, furnaces, vents, flares, etc.

Can it be recovered?

Can it be used?




Where is it?

Utility plant

Process unit

What is the environment?

Sensible

Latent

Acidic, etc.

Direct / Indirect contact

When is it available?

Continuous

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

BFW preheat

Blowdown / Makeup heat recovery

Combustion air preheat

Compressed air heat recovery Other..

Process side typically some level of pinch or optimization

is done and so the process is highly integrated

Preheat reaction feed streams

Preheat process water

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

Direct contact Closed loop

Industrial applications are seeing simple paybacks: 6 months- 2 years

Several installations, manufacturers, gas companies


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SuperBoiler?

Not a bigger boilerbut a b e t t e r boiler! Higher energy efficiency -

more than 95% HHV

Super-low emissions -down to 2 ppm NOxand 5 ppm CO

Smaller and lighter -reduce size and weight by

50 percent Competitive performance

Cost-effective

0

20

40

60

80

100

Typical

industrial

boiler

State of the

art*

2020 Super

Boiler

EnergyEfficiency,

NOx,ppmv

0

5

10

15

20

25

Footprint,s

qftperklb/hsteam

Efficiency Emissions Footprint

* Not all in the same boiler


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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

94% efficiency (from 70-83%)


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MVR / Thermal Compression

Main intent Recover latent energy of low pressuresteam

Mechanical Vapor Recompression

Boost the vented steam pressure via an electric motordriven compressor

Based on compression ratio, energy used by compressorcould be only 10-15% of boiler energy

Thermal Compression

Use of a converging-diverging nozzle

Needs motive steam

Called an Ejector when used to create vacuum


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Industrial Heat Pumps

http:/ / www1.eere.energy.gov/ industry/ bestpractices/ pdfs/ heatpump.pdf


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Industrial Heat Pumps

Heat Amplifier Will need

Motive heat (high temperature)

Waste heat Will provide

Medium temperature heat

Amount of heat provided will be sum of waste heat &

motive heat Temperature Amplifier

Will need Waste heat

Ambient temperature heat rejection

Will provide High temperature heat

Amount of heat provided will be difference between wasteheat & heat rejected to ambient


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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

f


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Refrigeration From Engine Waste Heat

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

Courtesy: Energy Concepts Company

Waste Heat Refrigeration


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Waste Heat Refrigeration

Installed in 1997

Recovers 200 barrels LPG per day

Double lift cycle, -25o

F from 280o

F liquidstream

Courtesy: Energy Concepts Company

Ammonia Absorption Refrigeration


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At comparable production levels, cost approximates vaporcompression $/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. Thismeans 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 withdebottleneck applications and increased recovery applications.

Ammonia Absorption Refrigeration

Adsorption Chiller


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Adsorption Chiller

HIJC USA, INC.

Adsorption Chiller


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Adsorption Chiller

HIJC USA, INC.

Challenges


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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


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Other Comments

Mechanical vapor recompression and thermalrecompression to reuse the waste heat indistillation overhead as a heat source for reboiling

Useful applications for waste steam at lowpressures, less than 20 psig

Understand where recovery of low level heat has

proven cost effective

RoundTable Discussion


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RoundTable Discussion

Documents

Roundtable 0906