Waste Heat Recovery in Process Industries

Hussam Jouhara is Full Professor of Thermal Engineering at Brunel University in London, UK. His research and professional foci are on the development of heat pipe-based heat exchangers with successful implementation in a multitude of temperature ranges, including cryogenic and high-temperature industrial waste heat recovery.

• Preface xiii1 Thermodynamic Cycles 11.1 Introduction to Thermodynamic Cycles 11.2 Rankine Cycle 11.2.1 Introduction 11.2.2 Thermodynamic Diagrams 21.2.3 The Carnot Cycle 101.2.4 Ideal and Actual Rankine Cycles 121.2.4.1 Ideal Cycle 131.2.4.2 Superheated Rankine Cycle 151.2.4.3 Actual Rankine Cycle 171.2.4.4 Improvements to the Rankine Cycle 191.2.4.5 Regenerative Rankine Cycles 221.2.4.6 Cogeneration 261.2.5 Other Configurations of the Rankine Cycle 291.2.5.1 Supercritical Rankine Cycles 291.2.5.2 Reverse Rankine Cycles 301.2.6 Rankine Cycles in Power Plants 311.2.6.1 Fossil Fuel Power Plants 311.2.6.2 Nuclear Power Plants 321.2.6.3 Overall Efficiency of a Power Plant 321.2.6.4 Case Studies 331.3 Organic Rankine Cycle 341.3.1 Configurations of ORC 351.3.1.1 Basic ORC Configuration 351.3.1.2 ORC with Preheating 361.3.1.3 Recuperative ORC 381.3.1.4 Recuperative ORC with Preheating 391.3.2 Organic Working Fluids 401.3.3 Organic Working Fluid Selection 421.3.4 Applications of the ORC 451.3.4.1 Waste Heat Recovery 451.4 Kalina Cycle 461.4.1 Cycle Fundamentals 461.4.1.1 Why Use Ammonia–Water Solution in Kalina Cycle? 481.4.2 Advantages and Drawbacks 491.4.2.1 Advantages 491.4.2.2 Drawbacks 501.4.3 Applications of the Kalina Cycle 501.4.3.1 The Different Configurations of the Cycle 511.4.4 Case Studies 531.5 Brayton Cycle 531.5.1 Regenerative Brayton Cycle (Regenerator) 571.5.1.1 Compressor Analysis 581.5.1.2 Turbine Analysis 581.5.1.3 Heat Supplied to the Cycle 591.5.2 Regenerative Brayton Cycle (Reheater and Intercooler) 591.5.2.1 Intercooling 601.5.2.2 Reheating 601.6 Chapter Summary 61References 622 Waste Heat Recovery 672.1 Burner and Air Preheaters 672.1.1 Recuperators 672.1.1.1 Recuperative Burners 682.1.1.2 Classifying Recuperative Burners 712.1.1.3 Efficiency Improvement and Fuel Savings 722.1.2 Regenerators 742.1.2.1 Rotary Regenerators 742.1.2.2 Static Regenerators 752.1.2.3 Regenerative Burners 752.1.3 Burner Technology Comparison 762.1.4 No X Formation 772.1.5 Run-Around Coil 782.2 Heat Exchangers 792.2.1 Shell and Tube HEXs 792.2.1.1 Construction 802.2.1.2 Applications and Limitations 822.2.2 Plate Heat Exchanger 822.2.2.1 Spiral Plate Heat Exchanger 832.2.3 Heat Pipe Heat Exchanger 832.2.4 Compact HEX 852.3 Waste Heat Boilers 862.3.1 Different WHB Designs 872.3.2 WHB Methodologies 882.3.2.1 Feed Water Preheating Effect 882.3.2.2 Optimising Thermodynamic Cycles 892.3.2.3 Heat Recovery Boiler with Water Spray Systems 912.3.3 Failure Modes 922.3.3.1 Failure Modes Analysis 922.4 Heat Recovery Steam Generators 932.4.1 Construction of Waste HRSG 942.4.1.1 HRSG Design and Construction 952.4.1.2 Evaporator 952.4.1.3 Superheater 962.4.1.4 Economiser 962.4.1.5 Steam Drum 962.4.1.6 Evaporator Types 962.4.1.7 Horizontal Tube HEXs 982.4.1.8 Natural Circulation HRSGs 982.4.1.9 Assisted (or Forced) Circulation HRSGs 992.4.1.10 Tube Materials 992.4.1.11 The ‘Pinch Point’ and Other Effects 1002.5 Heat Pumps 1002.5.1 Fundamental Principles of Heat Pumps 1002.5.1.1 Cooling Mode 1012.5.1.2 Heating Mode 1012.5.2 Variation of Heat Pump System 1022.5.2.1 Air Source Heat Pump System 1032.5.2.2 Ground Source Heat Pump System 1032.5.2.3 Water Source Heat Pump System 1052.5.2.4 Water Loop Heat Pump System 1052.5.2.5 Exhaust Air System 1062.5.2.6 Hybrid Heat Pump 1062.5.2.7 Solar-Assisted Heat Pumps 1062.6 Direct Electrical Conversion Device 1072.6.1 TEG – Working Principle 1082.6.2 The Seebeck Effect 1092.6.3 The Peltier Effect 1092.6.3.1 Applications of the Peltier Effect 1102.6.4 Thomson Effect 1102.6.5 Joule Heating 1112.6.6 Theoretical Principle 1122.6.7 Figure of Merit 1122.6.8 Fermi Level 1132.6.9 Nano-Sizing 1142.6.10 Efficiency of TEG 1152.7 Thermal Storage 1162.7.1 Sensible Heat Storage 1172.7.2 Latent Heat Storage 1202.7.3 Thermochemical Storage 1232.7.4 Phase Change Materials 1232.7.5 Organic Material 1252.7.6 Inorganic PCMs 1282.7.7 Eutectic PCMs 1282.7.8 PCM Methodologies 1292.7.8.1 Encapsulation of PCMs 1292.7.8.2 Microencapsulated PCMs 1292.7.8.3 Macroencapsulation of the PCMs 1322.7.8.4 Nanomaterial PCMs 1322.7.8.5 Shape Stabilisation 1352.8 Design Development Methods 1352.8.1 Introduction 1352.8.2 Heat Exchangers 1402.8.2.1 Local Heat Transfer 1402.8.2.2 LMTD Method 1472.8.2.3 Effectiveness-Number of Transfer Units (ε-NTU) Method 1512.8.3 Regenerative and Recuperative Burners 1522.8.3.1 Regenerative Burners 1542.8.3.2 Recuperative Burners 1562.8.4 Waste Heat Boilers 1572.8.5 Air Preheaters 1602.8.6 Heat Recovery Steam Generator 1662.8.7 Heat Pumps 1702.8.8 Direct Electrical Conversion Device 1732.8.9 Thermal Storage 176References 1783 Low-Temperature Applications 1913.1 Refrigeration 1913.2 Cryogenics 1983.2.1 Loop Heat Pipe 1993.3 HVAC 204References 2094 Medium-Temperature Applications 2134.1 Food Industry 2134.1.1 Energy Use in the Industry 2134.1.2 Case Study 1: Heat Recovery Potential of the Crisps Manufacturing Process 2144.1.3 Case Study 2: Temperature and Energy Performance of Open Refrigerated Display Cabinets Using Heat Pipe Shelves 2154.2 Ventilation 2214.2.1 Applications 2214.3 Solar Energy 2234.4 Geothermal Energy 2304.5 Automotive Industry 2334.5.1 Industrial Processes 2354.6 Aviation 237References 2395 High-Temperature Applications 2455.1 Steel Industry 2455.1.1 TEG Modules 2465.1.2 Heat Exchangers 2465.1.2.1 Application 1: Slag Particles Blast Furnace Retrofit 2465.1.2.2 Application 2: Flat Heat Pipe Heat Exchanger 2475.1.3 Recuperators 2495.1.3.1 Application 1: Heat Recuperator for Steel Slag 2495.2 Ceramic Industry 2515.2.1 Introduction 2515.2.2 Heat Exchangers 2515.2.2.1 Application 1: Radiative Heat Pipe 2515.2.2.2 Application 2: Multi-Pass Heat Pipe 2525.2.2.3 Application 3: Forced Convection Heat Pipe 2535.3 Cement Industry 2545.3.1 Gas Suspension Preheaters 2555.3.1.1 Application 1 2555.3.1.2 Application 2 2565.3.2 Heat Pipe Thermoelectric Generator 2565.4 Aluminium Industry 2585.4.1 Rotary Regenerator 2585.4.2 Heat Exchangers 2585.4.3 Heat Pumps 2585.4.4 Recuperators 2605.4.4.1 Radiative Recuperator 2605.4.4.2 Convective Recuperator 2615.4.4.3 Hybrid Recuperator 2625.4.5 Thermoelectric Device 2625.4.6 Regenerative Burner 2625.4.7 Preheating Scrap 2645.4.8 De-coating 265References 265Index 269