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23 views11 pages

Nav PUS WasteHeatRecovery

Uploaded by

Ajay Chauhan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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BUNDELKHAND INSTITUE OF ENGINEERING & TECHNOLOGY

JHANSI U.P.

TOPIC : WASTE HEAT RECOVERY IN PROCESS INDUSTRY

Submitted By:
Submitted to: Head Of Department
Navdeep Singh (2100430510006)
Dr. Ravindra Kumar Dr. Sudeep Yadav
Assistant Professor Associate Professor
Chemical Engineering Department Chemical Engineering Department
BIET Jhansi (UP) BIET Jhansi (UP)
Waste Heat Recovery in
Process Industries
Harnessing energy from waste heat is vital for sustainability and cost-efficiency in
process industries.
Why This Topic Matters
• Energy Efficiency

Waste heat recovery captures thermal energy lost during industrial processes and repurposes it for heating, cooling, or power generation,
reducing the need for additional energy inputs.

• Cost Savings

Utilizing waste heat lowers fuel and energy consumption, cutting operational costs. For energy-intensive industries, even small improvements
in heat recovery can translate into significant financial benefits.

• Environmental Impact

By reducing reliance on additional fuels, waste heat recovery lowers greenhouse gas emissions, promoting sustainability and compliance with
environmental regulations. It also eases the strain on energy grids, decreasing indirect emissions.

• Process Reliability

Recovered heat stabilizes energy use, enhancing operational consistency and reducing system variability. This improves productivity,
minimizes disruptions, and extends equipment life, ensuring efficient and reliable processes.
Introduction
• What is Waste Heat?

Waste heat refers to the energy generated during industrial processes that is not
utilized and dissipates into the environment.

In industrial processes, a significant amount of energy is often lost in the form of


waste heat. This unused energy is typically dissipated into the environment through
exhaust gases, cooling water, or radiative heat loss from equipment surfaces. Waste
heat represents a substantial inefficiency in energy use, as it is energy that could
otherwise be harnessed for productive purposes.It represents a significant energy
loss, often in the form of hot exhaust gases, cooling water, or unutilized heat in
stacks and other equipment.

• Key Points:

Originates from inefficiencies in energy conversion.


Commonly found in high-temperature exhaust streams and cooling systems.
Sources of Waste Heat
. High-Temperature Sources:

Exhaust gases from turbines, engines, and furnaces.


Flue gases from boilers and kilns.

2. Medium-Temperature Sources:

Cooling water from engines and compressors.


Steam condensate in heat exchangers.

3. Low-Temperature Sources:

Heat losses from pipelines, valves, and process equipment.


Warm air from HVAC systems.

Industry Examples
1. Cement Plants :High-temperature exhaust gases from kilns.
2. Steel Mills: Heat loss from blast furnace gases.
3. Petroleum Refineries: Heat dissipation in flares and stack emissions.
Waste Heat Recovery
Technologies
1. Heat Exchanger
Function: Transfer heat from a hot fluid to a cooler fluid without mixing them.
Applications: Preheating combustion air.
Heating process water.

2. Waste Heat Boilers


Converts high-temperature exhaust gases into steam or hot water.
Applications: Steam generation for industrial processes.
Power generation in combined heat and power (CHP) systems.

3. Thermic Fluid Systems


Uses specialized heat-transfer fluids to transport energy.
Ideal for indirect applications requiring high temperatures.

4. Advanced Technologies
Organic Rankine Cycle (ORC): Converts low-temperature heat into mechanical energy,
which is then used to generate electricity.

Absorption Chillers: Utilize waste heat for refrigeration and air conditioning.
Applications of Waste Heat
Recovery
1 1. Power Generation
Combined heat and power (CHP) systems use waste heat to produce
electricity and thermal energy simultaneously.
Example: Gas turbines with heat recovery steam generators (HRSG).

2. Process Heating
2 Waste heat is used for drying, distillation, and chemical reactions.Example:
Preheating feedwater for boilers.

3. Preheating Applications
Preheating air or fuel improves combustion efficiency.
Example: Preheating combustion air in furnaces.

3 4. District Heating
Captured waste heat supplies residential or commercial heating needs.
Example: Heat networks in urban areas powered by industrial plants.
Successful Case Studies

Cement Industry
1 Waste heat from kilns used to generate steam for power generation.

Steel Industry
2 Waste heat from steelmaking processes used to preheat materials.

Chemical Industry
3 Waste heat from reactors used to provide process heating.
Overcoming Implementation Challenges
Cost
1 Initial investment costs can be significant, but long-term savings often outweigh the initial
expense.

Technical Feasibility
2 Careful consideration of process parameters and compatibility with
existing infrastructure is essential.

Maintenance
Regular maintenance and inspections of waste heat
3
recovery equipment are crucial to ensure optimal
performance.
Benefits of Waste Heat
Recovery
Economic Benefits
Significant reductions in energy bills.
Enhanced profitability due to lower operating costs.

2. Environmental Impact
Reduces greenhouse gas emissions.
Supports corporate sustainability goals.

3. Operational Efficiency
Stabilizes energy supply within processes.
Reduces wear and tear on primary energy systems.
Conclusion
Waste heat recovery offers immense potential for cost savings and environmental benefits.
Technological advancements make it feasible for diverse industries.
Adoption is essential for achieving long-term sustainability goals.

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