Waste Heat Recovery Transcript

Waste Heat Recovery
Energy University Transcript

Slide 1
Welcome to Waste Heat Recovery.
Slide 2
This course contains calculations, and you may find it helpful to have a calculator, some scrap paper and a
pencil on hand while viewing.
Slide 3
For best viewing results, we recommend that you maximize your browser window now. The screen controls allow
you to navigate through the eLearning experience. Using your browser controls may disrupt the normal play of
the course. Click the paperclip icon to download supplemental information for this course. Click the Notes tab to
read a transcript of the narration.
Slide 4
At the completion of this course, you will be able to:
 List the factors that influence the feasibility of waste heat recovery
 Identify opportunities to recover waste heat, the temperature ranges of heat recovered and the possible
uses
 Perform calculations of waste heat recovery, and you will be able to
 Categorize and explain the general operation of the main equipment used to recover waste heat
Slide 5
Waste heat is generated in combustion and in processes in industries and then is typically discharged to the
environment. Waste heat is present in almost all industries and processes.
Opportunities exist to put this waste heat to some use economically and reduce energy consumption.
Many companies that did not find this heat worthwhile to use earlier—due to low fuel costs—may find it
economical now, due to high energy prices. It is critical to identify sources of waste heat and simultaneously find
practical and cost effective usage so that a link between availability and requirement can be established.
Slide 6
The direct benefit of waste heat recovery is:
 Reduced energy consumption and consequent increase in energy efficiency
 Using waste heat in a boiler, furnace or any process can result in lower fuel consumption and lower
costs
There are also indirect benefits, including:
 Lower greenhouse gas emissions—since fuel consumption is reduced—green house gas emissions will
also be reduced
 Reduction in pollution: in cases where toxic combustible waste is disposed of in incinerators the waste
gases may be used for heat recovery and there can be a reduction in the release of pollutants
 Reduction in equipment size as flue gases produced are in reduced quantities and consequently result
in reduction in sizes of fans, stacks, ducts, etcetera
©2012 Schneider Electric. All rights reserved. All trademarks provided are the property of their respective owners.
This reduction in equipment size also leads to a:
 Reduction in auxiliary energy consumption—as smaller fans do not require as much energy to operate
 Lastly, enhanced equipment life –when the process is properly executed, equipment life will be
extended, for example; some forms of heat recovery can reduce the load on heating and ventilation
systems
Slide 7
In any heat recovery project, it is essential that the heat recovery scenario is viable and economical. Economic
recovery would depend upon following factors:
 There must be a suitable use for the recovered heat
 The quantity must be adequate—meaning the amount of heat must be enough to make the project
worthwhile
 The quality of heat must be sufficient for proper use in the chosen process. Typically, this means the
waste heat has to be a high enough temperature to be adequate
 And there must be a cost effective transfer for source to end use—which often means that the target
process must be close enough to the source to be feasible and the heat must be generated in a timely
manner—or the plant must be able to store the heat efficiently and effectively
Slide 8
The cost effective transfer of the waste heat can be impacted by technical considerations, such as selection of a
suitable heat exchanger.
For waste heat recovery to be successful we need to extract the maximum amount of heat from the waste heat
stream and lower its final waste temperature as much as possible.
However there are practical limits, and side effects such as corrosion, fouling or plugging. We will see more
about this later in the course.
Slide 9
Waste heat can be available in many forms from low to high temperature. After chilled water is used for cooling
equipment, it may still be cool enough to be used for pre-cooling in some process – which in effect—is reverse
heat recovery.
Furnaces or combustion are potential sources of high temperature waste heat. Most often, the quality depends
on the temperature of waste heat available. The higher the temperature, the higher the quality, and hence more
cost effective utilization.
Slide 10
A mathematical calculation of waste heat availability is as given below:
Q=m x CP x ΔT x η
Where:
Q is the quantity of heat recovered in kcal/hr or BTU/hr
m is the mass flow rate of the fluid or gas in kg/hr or lb/hr
CP is the specific heat capacity of the fluid or gas in kcal/kg ºC or BTU/lb ºF
ΔT is the difference of heat recovered or temperature between inlet and outlet in ºC or ºF
η – the Greek letter ―eta‖ is the heat recovery factor, expressed as a percentage
Sometimes you might see the mass flow rate composed of two terms V x ρ
Where V is flow rate of substance in m³/hr or ft³/hr

and ρ is density of flue gas in kg/m³ or lb/ft³
We will see how to apply this equation later in the class.
Slide 11
What are some typical sources of waste heat?
Heat is found in waste gases from high temperature industrial processes, including direct fuel fired processes
such as metal refining or heating furnaces, cement kilns, glass melting, hydrogen plants or solid waste
incinerators.
Temperatures are typically in the range of 650 to 1500 ºC or 1200 to 2750 ºF.
Slide 12
The most customary source is combustion flue gas, which is typically a medium temperature source.
Most industries use fuel in boilers, furnaces or kilns and the quantity of flue gases is substantial—15 to 20 times
the fuel quantity.
Temperatures are high—normally in the range of 230 to 450 ºC or 450 to 850 ºF. The waste heat is readily
available in the plant and so is more convenient to use.
Slide 13
Here are some constraints which must be considered while using flue gases:
 Flue gases usually contain gases such as:
o Carbon monoxide (CO), carbon dioxide (CO2), sulphur dioxide (SO2), etcetera Which can—in
combination with moisture at lower temperatures—form acids and corrode the metals
 Heat exchangers made of special alloys may be necessary
 Flue gases contain some contaminants, which may foul the pipes and other passages. Heat exchangers
and other heat transfer equipment tend to result in a drop in pressure, and may need to be
supplemented by external means.
Macrofouling credit: Taprogge GmbH, Germany
Slide 14
Low temperature heat recovery is typically focused on:
Air conditioning and refrigeration, diesel generating sets, baking or curing ovens, air compressors, process steam
condensate, etcetera
Because it is usually difficult to extract heat directly from the source, low temperature heat recovery is useful only
for preheating, and because the heat is relatively low quality, it can’t be used in demanding processes, but it
could be used to preheat outside air entering a furnace, or begin to warm substances entering a process.
Slide 15
It is important to note that low temperature heat recovery is more difficult to use, however employing an industrial
heat pump may increase that viability as well as quality. We’ll see how later on.
Furthermore, absorption refrigeration processes typically can use heat with temperatures approximately between
85 and 200 degrees Celsius (185 to 392 degrees Fahrenheit). Low to medium temperature heat can be used in
economizers. Economizers use the exhaust heat from the boiler as a heat source to pre-heat feed water for the
boiler.
Diagram credit: The Natural Gas Boiler Burner Consortium
Slide 16
Other sources of waste heat include water cooled chillers, as these machines reject a significant amount of heat
energy through cooling towers. This energy is at a very low temperature for direct use.
Slide 17
The waste heat stream may include both sensible and latent heat.
Sensible heat, sometimes referred to as ―simple heat‖, is based on the temperature of the air, gas or other
substance, which can be measured with a typical thermometer.
Latent heat is contained in the moisture content in the air or gas. Latent means hidden. For example, when we
boil water, it evaporates into steam. The energy used to boil the water and make it change state into steam is
now ―hidden‖ in the steam. Latent heat is the energy required to make a substance change state.
The total heat energy content of moist air or gas is referred to as "enthalpy". This takes into account both
temperature (sensible heat) and humidity levels (latent heat).
To learn more about sensible heat, latent heat and enthalpy, see our class on "HVAC and the Characteristics of
Air".
Slide 18
Waste heat can be put to use—depending upon the type of plant and category of heat available—especially in
relation to temperature and quantity. Let’s take a moment and discuss the different ways waste heat can be put
to use, including:
 Pre-heating combustion air
 Pre-heating boiler feed water
 Vapour absorption refrigeration, and
 Pre-heating for process requirements
Slide 19
One of the most common uses for waste heat is the pre-heating of combustion air. Using pre heated combustion
air will improve the efficiency of the combustion—resulting in the reduction of energy consumption in boilers and
other direct fuel fired equipment.
Slide 20
The second common use for waste heat is through the pre-heating of boiler feed water, and is commonly done in
most boilers. Pre-heating of feed water will reduce the fuel consumption resulting in enhanced energy efficiency.
In the case of closed loop steam systems—condensate water is returned to the boiler and is already at
sufficiently high temperature—there, pre-heating would be relevant for makeup water added to the system.
Vapour Absorption Refrigeration is the third common use of waste heat. Whilst in conventional refrigeration, input
is mechanical power, in a vapour absorption system, heat is utilised for producing refrigeration. This is the
preferred option in facilities or industries which require a high volume of refrigeration or air conditioning and
simultaneously have waste heat available.
Pre-heating for process requirements include:

 Many chemical and other industrial processes that require hot fluids, air or water, or other processes
where
 Waste heat can be most appropriately used
Diagram credit: U.S. Department of Energy
Slide 21
There are three basic elements a waste heat recovery system must possess in order for the system to be
developed. These include:
 Compatibility
 Scheduling, and
 Location
Let’s discuss each one in more depth.
Slide 22
When it comes to compatibility of waste heat quality, the quality of waste heat energy must be better than, or
equal to the energy required for end use. High temperature usage would require waste heat of matching
temperature. However, low or medium temperature use can be met with high temperature heat.
Slide 23
Scheduling is another consideration in waste heat recovery. For example, quite often, the manufacture of waste
heat may not be continuous. Likewise, usage may also be intermittent. It will then be essential to match the
requirement with availability (where waste heat availability or usage is intermittent). Maximum efficiency of waste
heat utilization would be accomplished when generation and usage correspond.
Case in point—if the boiler flue gases are used for heating combustion air, or feed water—the arrangement
would be excellent because both are part of the same system and come into use when the boiler is operating.
If the schedule of waste heat generation and utilisation does not correspond, some form of thermal storage
would be necessary. Thermal storage is costly and not a preferred option.
Slide 24
Location is the third consideration in our waste heat recovery equation. Physical proximity between availability of
waste heat and usage is ideal for achieving best efficiency. Long distances for transferring heat in any form
would result in expensive system installation.
Slide 25
Waste heat recovery has been practiced in industries for a long time which has resulted in the development of
many devices to suit the requirements. Let’s explore the typical devices.
Slide 26
In recuperators, heat exchange takes place between flue gases and air through metallic or ceramic walls. Ducts
or tubes carry air—which has to be preheated. The opposite side contains waste heat in the form of flue gases.
Stack losses are reduced by lower gas temperatures and also by discharging diminished quantities of exhausted
gases due to fuel savings.
Heat transfer from hot gases to the inner surface takes place through radiation while heat transfer to cold air
takes place through convection.
Here is a recuperator. It is used for recovering waste heat from flue gases. There are different types of
recuperators, so let’s explore those next.
Diagram credit: SEAV
Slide 27
The simplest configuration for a recuperator is the metallic radiation recuperator, which consists of two concentric
lengths of metal tubing as shown here.
The inner tube carries the hot exhaust gases while the external annulus carries the combustion air from the
atmosphere to the air inlets of the furnace burners.
The hot gases are cooled by the incoming combustion air, which immediately carries additional energy into the
combustion chamber. This is energy which does not have to be supplied by the fuel and consequently, less fuel
is burned for a given furnace loading. The savings in fuel also means a decrease in combustion air and as a
result, stack losses are diminished—not only by lowering the stack gas temperature—but also by discharging
smaller quantities of exhausted gas.
Diagram credit: Harditech Group
Slide 28
The radiation recuperator gets its name from the fact that a substantial portion of the heat transfer from the hot
gases to the surface of the inner tube takes place by radiative heat transfer. The cold air in the annulus, however,
is almost transparent to infrared radiation so that only convection heat transfer takes place to the incoming air.
As shown in the diagram, the two gas flows are usually parallel, although the configuration would be simpler and
the heat transfer would be more efficient if the flows were counter flowing –or opposed in direction. The reason
for the use of parallel flow is that recuperators commonly serve an additional function of cooling the duct—
carrying away the exhaust gases—and, as a result, extend its service life.
Diagram credit: Harditech Group
Slide 29
The primary limitation on the heat recovery of metal recuperators is the reduced life of the liner at inlet
temperatures exceeding 1100 degrees Celsius (2000 ºF). As a result, ceramic tube recuperators have been
developed to address the temperature limitations of metal recuperators. Ceramic materials allow operation on the
gas side to be at 1550 degrees Celsius (2800 ºF) and to be 815 degrees Celsius (1500 ºF) on the preheated air
side.
The new designs are reported to last two years with air preheat temperature as high as 7000 degrees Celsius
(12600 ºF), along with much lower leakage rates.
Diagram credit: Department of Coal, India 1985
Slide 30
Another frequent design for recuperators is the convective recuperator as shown here. In this configuration, hot
gases are passed through a number of parallel tubes of small diameter while incoming air passes through the
outer shell surrounding the tubes. The incoming air passes over hot tubes multiple times in direction normal to
the axis of the tubes.
Diagram credit: Reay, D.A. 1996
Slide 31
For maximum heat transfer, a blend of convective and radiation design may also be used. These are termed
―hybrid recuperators‖ In this array, a high temperature radiation recuperator is followed by a convective type.
To overcome the limitations of metals (metals typically operate in the range of 1000ºC or1800ºF), ceramics are
used—which can operate at 1300 degrees Celsius (2400ºF). These are more expensive than simple metallic
radiation recuperators, but are less cumbersome.
Diagram credit: Reay, D.A. 1996
Slide 32
In the case of boilers, an economizer is used to utilize waste heat from flue gases to pre-heat boiler feed water.
The rule of thumb is that for every 22 degrees Celsius (64ºF) reduction in flue gas temperature—by passing
through an economizer—there are 1% savings on boiler fuel.
Diagram credit: Bureau of Energy Efficiency
Slide 33
Waste heat boilers are water tube boilers—where hot exhaust gases from gas turbines, incinerators, etcetera—
pass over a number of parallel tubes containing water. Water is evaporated in the tubes and collects in a steam
drum. This is then drawn off for use in heating or process steam.
In gas based power plants, the waste heat boilers are used after gas turbine generation to further operate a
steam turbine to generate power. Thus, the efficiency of a gas based power plant is enhanced by nearly 50%.
Diagram credit: Canada Agriculture and Agri-Food
Slide 34
In the devices discussed previously, heat is transferred from high temperature fluid to a fluid at lower
temperature. After each transformation, energy becomes less and less usable. As a general rule of thumb, a fluid
temperature of 120 degrees Celsius (250ºF) is considered the limit for heat recovery. However, as fuel costs
continue to rise worldwide, even such fluids can be used economically.
Slide 35
Heat pumps are useful where both heating and cooling are simultaneously required. One such example is in the
plastics industry where water after being used in a cooling injection moulding machine is used to provide space
heating.
Slide 36
It is feasible to reverse the direction of energy flow by means of a heat pump. In this device, after a fluid flows
through an evaporator, it is completely vaporised.
Low temperature vapour is compressed with external energy input—raising its temperature and pressure. The
vapour flows through a condenser releasing its energy to become a liquid. This liquid is expanded through an
expansion valve back to the evaporator. It is something like an air conditioner running in reverse. Heat pumps
have the ability to upgrade heat to a value double that of energy consumed.
Slide 37
A regenerator is a form of thermal energy storage. Imagine a rechargeable battery – but containing heat rather
than power. It’s ideal for large capacity situations such as glass and steel melting furnaces.
A regenerator is an insulated container containing bricks of metal or ceramic to store heat. The bricks are
heated by exhaust gases or fluids from the process. Eventually, the regenerator is fully charged with heat. The
exhaust gas or return fluids are then shut off, and instead intake air is allowed to flow through the unit. The air is
pre-heated by the regenerator before it goes to the furnace.
Eventually, the heat is discharged from the regenerator and needs to be ―recharged‖. Then, the intake airflow is
turned off and the exhaust gases or return fluids are switched back on. This switchover is called a ―reversal‖.
Diagram credit: Department of Coal, India, 1985
Slide 38
The size of the regenerator depends upon the period of time between reversals, thickness and conductivity of the
brick, as well as heat storage ratio of the bricks Larger ones have a higher cost. If it is desired to have the
regenerator available continuously, then at least two will be required—so that their operation can be alternated—
one providing heat while the other is recharging.
Diagram credit: U.S. Department of Energy
Slide 39
Heat wheels are used extensively in low to medium temperature heat recovery systems. A disc rotates between
a hot gas duct and a cold air duct which are installed side-by-side. As the disc rotates, the heat is transferred
from the hot gas to the cold air. A drawback of this configuration, is that odors can be an issue for the heat wheel
due, to transferred air or molecules on the wheel.
Diagram Credit: Englehard ICC Corp

Diagram Credit: SADC, 1999
Slide 40
Heat pipes are another type of waste heat recovery. These are capillary tubes used for liquids and gases at all
temperatures and are often bundled with air conditioning ducts. In colder climates, they have excellent payback.
Thermal energy applied to the surface at one end, causes fluid near the surface to evaporate—absorbing the
latent heat of vaporisation. At the other end of the pipe, thermal energy is removed—causing vapour to liquefy—
giving up latent heat.
A heat pipe can transfer up to 100 times more thermal energy than copper, the best-known conductor.
Additionally, the heat pipe is a thermal energy absorbing and transferring system—having no moving parts—and
hence requires minimal maintenance.
Photo Credit: Advanced Cooling Technologies, 2010

Diagram Credit: SADC, 1999
Diagram Credit: B.L. Capehart, et. al., Guide to Energy Management, 5th ed., Fairmont Press, 20003, p. 253
Photo Credit: NASA
Slide 41
The heat pipe is made up of three elements
 A sealed container
 A capillary wick structure and
 Working fluid
The capillary wick structure is fabricated integrally into the inner surface of the container tube, and sealed under
a vacuum. Thermal energy applied to the external surface of the heat pipe is in equilibrium with its own vapour—
as the container tube is sealed under vacuum.
Diagram Credit: Chresources, 2008
Slide 42
Thermal energy—applied to the external surface of the heat pipe—causes the working fluid near the surface to
evaporate immediately. Vapour thus formed absorbs the latent heat of vaporization, and this part of the heat pipe
becomes an evaporator region. The vapour then travels to the other end the pipe—where the thermal energy is
isolated causing the vapour to condense into liquid again—and in so doing—giving up the latent heat of the
condensation. This part of the heat pipe works as the condenser region. The condensed liquid then flows back to
the evaporated region.
Diagram Credit: Energy Spectrum UK
Diagram Credit: Acrolab Ltd.
Slide 43
Additional waste heat recovery equipment that you may encounter includes:
A checkerwork regenerator – which is a regenerator with checkerwork brick structure
A combined convective-radiative recuperator –which is a combination of recuperators explained earlier
Run-around loops : Run-around loops are similar to a heat pipe exchanger—with intermediate heat transfer fluid
in the coil—which has its two ends in hot and cold streams respectively
Checkerwork regenerator diagram credit: Society of Glass Technology
Combined convective-radiative recuperator diagram credit: Reay, D.A. 1996
Run-around loop diagram credit: Smith Group
Slide 44
Here is a chart, denoting the typical sources and utilisation of waste heat.
Slide 45
Here is a matrix of the various waste heat recovery devices and applications that we have been discussing. To
download a copy of these items, click the paperclip icon. (The paper clip icon is located in the lower right hand
corner of your toolbar.)
Slide 46
Now let’s look at an example of how to calculate waste heat recovery. As we discussed earlier, to determine how
much waste heat is available say from waste hot water, it is advisable to conduct a simple waste heat recovery
calculation. To do this you will need to measure the difference between inlet temperature and outlet temperature
of waste water through the heat recovery device.
Slide 47
Here is a basic equation to determine the available quantity of heat:
Q=m x CP x ΔT x η
Where:
Q is the quantity of heat recovered in kcal/hr or BTU/hr
m is the mass flow rate of the fluid or gas in kg/hr or lb/hr
CP is the specific heat capacity of the fluid or gas in kcal/kg ºC or BTU/lb ºF
ΔT is the difference of heat recovered or temperature between inlet and outlet in ºC or ºF
η – the Greek letter ―eta‖ is the heat recovery factor, expressed as a percentage
Sometimes you might see the mass flow rate composed of two terms V x ρ
Where V is flow rate of substance in m³/hr or ft³/hr

and ρ is density of flue gas in kg/m³ or lb/ft³
Slide 48
The heat recovery factor requires further explanation, so let’s delve into that now.
To determine the heat recovery factor take the actual heat transfer to cold fluid and divide it by the maximum
possible heat transfer.
η= Actual heat transfer to cold fluid

Maximum possible heat transfer
While maximum possible heat transfer can be calculated from total heat in waste water, actual transfer or
effectiveness will depend on the heat exchanger design, and is usually given in the specifications of the device.
A copy of these equations are available for download by clicking on the paperclip icon. Please do that now,
because we’ll be using these equations in our case study.
Slide 49
It is important to note that:
 Effectiveness generally increases with the heat exchanger area
 But this does not happen in a linear fashion, and
 At some point, a large area increase will only produce a small effectiveness increase
Heat transfer factors typically range between 50% and 90%.

(50% < η < 90%)
Slide 50
Now let’s take a look at a real life case study example. We’ll provide these examples using both US customary
units and metric units. Due to rounding during the calculations, you will find that the answers are slightly
different—depending on the units used. These differences are not significant for the purposes of these exercises.
Slides 51-55 show the Metric unit case study

Slides 56-60 show the U.S. customary unit case study example
Slide 51
A ferrous industry in India identifies an opportunity to save money by recovering heat from hot flue gas. By
performance analysis of a hot air generator, it is understood that the dry flue gas loss of the system is high—it is
because of the high temperature flue gas leaving from the hot air generator. High flue gas loss leads to an
inefficiency of the hot air generator and high fuel consumption.
Presently the combustion air is supplied at ambient temperature to the hot air generator. A good rule of thumb to
remember is that for every 18 degrees Celsius rise in combustion air, we will save 1% of fuel consumption.
Recovering the heat of the flue gases will reduce the dry flue gas losses, increase the efficiency of the furnace
and reduce furnace oil consumption. Hence, the owner decides to recover the heat of the flue gases to pre-heat
the combustion air to 180 degrees Celsius.
Slide 52
How much will the owner save in fuel costs by increasing the combustion air temperature from 35 degrees
Celsius to 180 degrees Celsius? Here is some necessary information for you to solve the case study:
 The present flue gas temperature=345 degrees Celsius

 The present combustion air temperature=35 degrees Celsius
 The present annual fuel consumption=250 Kilo Litres
 The proposed combustion air temperature=180 degrees Celsius
 And the fuel cost=$435 per Kilo Litres
Remember, an increase in combustion temperature of 18°C will provide you with 1% savings.
First, we need to figure out the difference in temperature. Take a moment and figure that out now.
Slide 53
Did you take 180°C - 35°C = 145°C ? If so, great job!
Next, we need to figure out our savings. Take a moment and figure out that now…and remember, an increase in
combustion temperature of 18°C will provide you with 1% savings.
Slide 54
Did you divide 145°C by 18°C to get 8%?
If so, you did the calculation correctly!
Now you need to compute the annual cost reduction. Take a moment now and figure it out.
Here’s the equation again, in case you need it:
Annual Cost Reduction=

Savings % x fuel(in kl) x (fuel cost $/kl)
Slide 55
Did you take 0.08 and multiply it by 250 kl and multiply that by the sum of ($435/ kl) to get $8,760 ? If so, good
job! Now you can review the same case study in U.S. customary units or proceed to some additional case
studies.
Slide 56
A ferrous industry in India identifies an opportunity to save money by recovering heat from hot flue gas. By
performance analysis of a hot air generator it is understood that the dry flue gas loss of the system is high—it is
because of the high temperature flue gas leaving from the hot air generator. High flue gas loss leads to an
inefficiency of the hot air generator and high fuel consumption.
Presently, the combustion air is supplied at ambient temperature to the hot air generator. A good rule of thumb to
remember is that for every 32 degrees Fahrenheit rise in combustion air we will save 1% of fuel consumption.
Recovering the heat of the flue gases will reduce the dry flue gas losses, increase the efficiency of the furnace
and reduce furnace oil consumption. Hence, the owner decides to recover the heat of the flue gases to pre-heat
the combustion air to 350 degrees Fahrenheit.
Slide 57
How much will the owner save in fuel costs by increasing the combustion air temperature from 95ºF to 350ºF?
Here is some necessary information for you to solve the case study:
 The present flue gas temperature=650ºF
 The present combustion air temperature=95ºF
 The present annual fuel consumption= 60,000 gallons
 The proposed combustion air temperature=350ºF
 The fuel cost= $1.81 per gallon
Remember, an increase in combustion temperature of 32°F will provide you with 1% savings.
First, we need to figure out the difference in temperature. Take a moment and figure that out now.
Slide 58
Did you calculate the difference in temperature by taking
350°F - 95°F = 255°F?
If so, good job! Now we need to determine the savings. Take a moment and calculate this now…and remember,
an increase in combustion temperature of 32°F will provide you with 1% savings.
Slide 59
Did you derive the savings by dividing 255°F by 32°F to get 8 %?
If so, you are correct!
Now we need to calculate the annual cost reduction. Here is the equation in case you need it:
Annual Cost Reduction=
Savings % x fuel gallons x (fuel cost$/gallon)
Slide 60
Did you take 0.08 and multiply it by 60,000 gallons and then multiply that answer by of $1.81 per gallon to get an
answer of $8,654?
Great job! Now you can review the same case study in metric units or proceed to some additional case studies.
Slide 61
We have also provided you with an additional case study to practice calculating waste heat. This case study
deals with a beer manufacturing company who has identified an opportunity to save money by recovering heat
from hot wort vapour coming from the external wort boiler (EWB). In the present scenario, hot wort vapour of
1560 kg/h at 108°C (3440 lb/hr at 226°F) is vented to the atmosphere after boiling in the EWB. Rather than
discharging this wort vapour to the atmosphere, three possible methods were identified to use the available heat
energy in the wort vapour:
 Preheat the wort before entering the EWB
 Raise the temperature of the water in the bottle washer and pasteuriser, or
 Increase the temperature of the boiler feed water—resulting in reduced steam and furnace oil
consumption
Click the paperclip icon to work on the case study. (We’ve provided a ―working excel‖ worksheet for you to work
on. Once you’ve worked out the answers, feel free to take a look at the answer sheet provided to verify your
accuracy.)
Beer Manufacturing Photocredit: Vclaw

Wort Photocredit: Ildar Sagdejev
Slide 62
Now, let’s summarize some of the information that we have learned in this course.
Today, we listed the various factors that influence the feasibility of waste heat recovery, including:
Suitable use
 Adequate quantity and quality
 Cost effective transfer—which takes into account the compatibility of the source and use, scheduling of
heat production, and location
We also identified the various opportunities to recover waste heat, the temperature ranges of heat recovered and
the possible uses for the recovered waste heat including:
 Pre-heat combustion air
 Pre-heat boiler feed water and
 Vapour absorption refrigeration
We then categorized and explained the general operation of the main equipment used to recover waste heat;
including:
 Recuperators
 Economizers
 Waste Heat Boilers
 Heat Pumps
 Regenerators
 Heat Wheels
 Heat Pipes, as well as the additional waste heat recovery equipment that you may encounter
Finally, we reviewed the process to calculate waste heat recovery.
Slide 63
Thank you for participating in this course.

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Waste Heat Recovery

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Where V is flow rate of substance in m³/hr or ft³/hr

We will see how to apply this equation later in the class.

Macrofouling credit: Taprogge GmbH, Germany

Diagram credit: The Natural Gas Boiler Burner Consortium

Pre-heating for process requirements include:

Diagram credit: U.S. Department of Energy

Diagram credit: SEAV

Diagram credit: Harditech Group

Diagram credit: Harditech Group

Diagram credit: Department of Coal, India 1985

Diagram credit: Reay, D.A. 1996

Diagram credit: Reay, D.A. 1996

Diagram credit: Bureau of Energy Efficiency

Diagram credit: Canada Agriculture and Agri-Food

Diagram credit: Department of Coal, India, 1985

Diagram Credit: Englehard ICC Corp

Photo Credit: Advanced Cooling Technologies, 2010

Where V is flow rate of substance in m³/hr or ft³/hr

η= Actual heat transfer to cold fluid

Heat transfer factors typically range between 50% and 90%.

Slides 51-55 show the Metric unit case study

 The present flue gas temperature=345 degrees Celsius

If so, you did the calculation correctly!

Here’s the equation again, in case you need it:

Annual Cost Reduction=

If so, you are correct!

Beer Manufacturing Photocredit: Vclaw

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