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Woldia University

West heat recovery project

INTRODUCTION

WEST HEAT RECOVER FOR HEATING PURPOSE

Waste heat is heat, which is generate in a process by methodof fuel combustion or chemical
reaction, and then “dumped”into the environment even though it could still be reuse forsome
valuable and economic purpose. The fundamentalquality of heat is not the amount but rather its
“value”. Thestrategy of how to recover this heat depends in part on thetemperature of the
wasteheat gases and the financial sideinvolved.Large amount of hot flue gases is generated
fromBoilers, Kilns, Ovens and Furnaces. If some of this wasteheat could be recovered, a
significant amount of primaryfuel could be saved. The energy lost in waste gases cannot
be fully recovered. However, much of the heat could be recovered and loss minimized
byadopting following measuresas outlined in this paper

Waste heat recovery methods include capturing and transferring the waste heat from a process
with a gas or liquid back to the system as an extra energy source [5]. The energy source can be
used to create additional heat or to generate electrical and mechanical power [6].Waste heat can
be rejected at any temperature; conventionally, the higher the temperature, the higher the quality
of the waste heat and the easier optimization of the waste heat recovery process. It is therefore
important to discover the maximum amount of recoverable heat of the highest potential from a
process and to ensure the achievement of the maximum efficiency from a waste heat recovery
system
There are many different heat recovery technologies available which are used for capturing and
recovering the waste heat and theymainly consist of energy recovery heat exchangers in the form
of waste heat recovery unit. These units mainly comprise common wasteheat recovery systems
such as air preheaters including recuperate, regenerators, including furnace regenerators and
rotary regenerators or heat wheels and run around coil, regenerative and recuperative burners,
heat pipe heat exchangers, plate heat exchangers, economizers, waste heat boilers and direct
electrical conversion devices. These units all work by the same principle to capture, recover and
exchange heat with potential energy content in a process.
Regenerative and recuperative burners
Regenerative and recuperative burners optimize energy efficiency by incorporating heat
exchanger surfaces to capture and use the waste heat from the hot flue gas from the combustion
process [8]. Typically, regenerative devices consist of two burners with separate control valves,
which are connected to the furnace and alternately heat the combustion air entering the furnace.
The system works by guiding the exhaust gases from the furnace into a case which contains
refractory material such as aluminum oxide [9]. The exhaust gas heats up the
aluminum oxide media and the heat energy from the exhaust is recovered and stored. When the
media is fully heated, the direction of the flue gas is reversed, with the stored heat being
transferred to the inlet air entering the burner and the burner with hot media starts firing.
Combustion air from the hot media then heats up the cooler media and the process starts again.
Through this technique, the regenerative burner can save the fuel needed to heat the air and this
improves the efficiency of combustion [10] (see Fig. 2).Burners that incorporate recuperative
systems are also used commercially. A recuperative burner has heat exchanger surfaces as part of
the burner design, which captures energy from the heated gas that passes through the body of the
burner [12]. The burner uses the energy of waste gas from the exhaust to preheat the combustion
air before it gets mixed with the fuel. The burners consist of an internal heat exchanger with
various features such as grooves, counter current flow and fins, which are used to establish
thermal contact between the waste exhaust gases and the combustion air coming from the supply
pipe [13]. The design works by collecting the both the exhaust gas and waste heat from the body
of the burner nozzle, and using them both to transfer heat into the combustion air. This air
preheating results in an improved efficiency of combustion and thus more heat from the nozzle.
It should be noted that the burner and the nozzle are inserted into the furnace body and the waste
heat is transferred to the burner by convection from the exhaust gases. Osaka Gas demonstrates
that for a furnace with a temperature of 1000 °C the air can be preheated to at least 500 °C,
indicating a considerable improvement of thermal efficiency
Economizers
Economizers or finned tube heat exchangers that recover low –medium waste heat are mainly
used for heating liquids. The system consists of tubes that is covered by metallic fins to
maximize the surface area of heat absorption and the heat transfer rate [15].The system is located
in the duct carrying the exiting exhaust gases and it absorbs the waste heat by letting the hot
gases pass through different sections covered by the finned tubes. Liquid is passed through the
tubes and it captures heat from the finned tubes. The hot liquid is then fed back to the system,
maximizing and improving the thermal efficiency [16]. Based on a study conducted by Spirax
Sarco [17], it is shown that if an economizer is used for a boiler system, it can increase the
efficiency by 1% for every 5 °C reduction of flue gas temperature. This indicates that the fuel
consumption of the system can be reduced by 5 –10% with a payback period of less than 2years
[18]. Economizers recover the waste heat and improve the efficiency of a system by preheating
the fluid in the system such as the feed water in a steam generator or a boiler, so less energy is
required to achieve the boiling temperature. In another study by Maxxtec [19], it is noted that
regardless of the design of the system, if the temperature of the flue gas is reduced by 140 °C, the
fuel consumption can be reduced by 7%.It is investigated that several different types of
economizers are available for different applications but they have the same functionality[20].
These designs include finned tubes, coiled tubes, non-condensing and condensing economizers.
The condensing and non-condensing
types are mainly used to improve the efficiency of boiler systems, whereas the other types are
commonly used in thermal power plants and large processing units to recover waste heat from
the flue gas. Having mentioned that, Vandergrift [21] investigates, economizers that are used for
low-temperature heat recovery namely as deep economizers are also available that are made out
of advanced materials such as Teflon, carbon and stainless-steel tubes and can withstand the
acidic condensate deposition on the surface of the heat exchanger. Glass-tubed economizers are
on the hand used for gas to gas heat recovery and for low to medium temperature applications
[22] .

Air preheaters
Air preheaters are mainly used for exhaust-to-air heat recovery and for low to medium
temperature applications. This system is particularly useful where cross contamination in the
process must be prevented. Such applications can include gas turbine exhausts and heat recovery
from furnaces, ovens, and steam boilers [27] .Air preheating can be based on two different
designs, the plate type and the heat pipe type. The plate type consists of parallel plates that are
placed perpendicular towards the incoming cold air inlet. Hot exhaust air is fed into the channels
between the plates, transferring heat to the plates and creating hot channels, through which the
cold air is passed. The heat pipe type on the other hand consists of a bundle of several sealed
pipes placed in parallel to each other in a container. The container is split into two sections
accommodating cold and hot air, inlet and outlet. The pipes inside the container accommodate a
working fluid which when faced with the hot waste gas at one end of the pipes, evaporates and
moves towards the other end of the pipe where cold air is passing [28] .These results in heat
being absorbed at the hot section of the pipe, which is transferred to the cold section, heating the
cold moving air over the pipes. The working fluid then condenses and moves towards the hot
section of the pipe, repeating the cycle [29] .As Nicholson [30] explain, there are mainly three
commonly used types of air preheaters which are classified as regenerators, including rotary
regenerators, run around coil, and recuperative. These technologies all function with the same
principle as air preheaters, however, have different configurations and used for different purposes
Heat exchangers
are devices that facilitate the exchange of heat between two fluids that are at different
temperatures while keeping them from mixing with each other. In heat exchangers, there are
usually no external heat and work interactions. Heat exchangers are commonly used in practice
in a wide range of applications, from heating and air conditioning system in household, to
chemical processing and power production in large plants. Heat exchangers differ from mixing
chambers in that they do not allow the two fluids involved to mix. Heat transfer in a heat
exchanger usually involves convection in each fluid and conduction through the wall separating
the two fluids. In the Analysis of a heat exchanger, it is convenient to work with an overall Heat
transfer co-efficient U, that accounts for the contribution of all these effects on heat transfer eat
exchanger

types of heat exchanger

Shell and Tube Heat Excanger

This type of heat exchanger is said to have originated
from the jacketed coil distiller. Shell and tube heat exchanger is an indirect contact type heat
exchanger. In this we make use of both parallel and counter flow . Shell and tube heat
exchangers in various sizes are widely used in industrial operations and energy conversion
systems. As the name suggests this type of heat exchangers consists of a shell (a large
pressure vessel) with a bundle of pipes inside it. The shell is a
container for the shell fluid. Usually, it is cylindrical in shape with a circular cross section
Basic components of a shell and tube heat
exchanger
The major components of a shell and tube heat
exchangers are tubes (tube bundles), tube sheets, shell,
impingement plates, channel covers, baffles.

1. TUBES :The tubesare the basic components of the

shell and tube heat exchanger, providing the heat
transfer surface between one fluid flowing inside
the tube and the other fluid flowing across the
outside of the tubes. It therefore recommended that
the tubes material should be highly thermal
conductive otherwise proper heat transfer will not
occur. The tubes may be seamless or welded and
most commonly made of copper or steel alloys.
2. TUBE SHEETS: The tubes are held in place by
being inserted into holes in the tubes sheets and
there either expanded into grooves cut into the holes
or welded to the tube sheet. The tube sheet is
usually a single round plate of metal that has been
suitably drilled and grooved to take the tubes
however where the mixing between two fluids must
be avoided, a double tube sheet may be provided.
The space between the tube sheets is open to the
atmosphere so any leakage of either fluid should be
quickly detected. The tube sheet must withstand to
corrosion .The tube sheets are made from low
carbon steel with a thin layer of corrosion resisting
alloy metallurgic ally bounded to one side.
3. SHELL: The shell is simply the container for the
shell side fluid, and the nozzles are the inlet and exit
ports. The shell normally has a circular cross section
and is commonly made by rolling the metal plate of
appropriate dimensions in to cylinder and welding
the longitudinal joint. In large heat exchanger , the
shell is made out of low carbon steel wherever
possible for the reason of the economy, though
other alloys can be and are used when corrosion or
to high temperature strength demand must be made.
4. IMPINGEMENT PLATES: When the fluid under
high pressure enters the shell there are high chances
that if the fluid will directly impinge over the tubes
then their breakage or deformation may occur. To
avoid the same impingement plates are installed to
waste the kinetic energy of fluid upto some extent
International Journal of Scientific Research in Science, Engineering and Technology
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341
so that fluid may impact the tubes with lower
velocity.
5. CHANNEL COVERS: The channel covers are
round plates to bolt to the channel flanges and can
be removed for the tube inspection without
disturbing the tube side piping. In smaller heat
exchangers, bonnets with flanged nozzles or
threaded connections for the tube side piping are
often used instead of channel and channel covers.
6. BAFFLES: Baffles serve two functions: Most
importantly, they support the tubes in the proper
position during assembly and operation and prevent
vibration of the tubes caused by flow induced
eddies, and secondly, they guide the shell side flow
back and forth across the field, increasing the
velocity and heat transfer coefficient.

Statement of problem
Literature review
Mirko et al (2011) have presented a systematic methodology totarget and design waste heat
recovery and reuse in industrial zones comprisedof multiple plants. The methodology first
establishes available waste heatqualities and reuse feasibilities considering distances between
individualplants. A targeting optimization problem in the form of a simple linearprogram is
solved to establish the maximum possible waste heat recovery forthe industrial zone.
Kabir et al (2010) have conducted thermal energy audit analysis onthe pyroprocessing unit of the
cement plant and found that the fuelcombustion provides 95.48% of the total energy input to the
unit. Fuelconsumption and energy cost are crucial for the clinker production energymanagement.
The kiln exist gases and kiln shell are the major sources ofthermal energy losses, amounting to
27.9% and 10.84 % respectively. Thethermal efficiency of the unit is 41%, low enough to
consider implementingthermal energy conservations measures. Therefore, the energy audit
isemphasized to be a medium for identifying areas of energy savingopportunities.

Augustine et al (2007) have studied the district heating systemsusing residual industrial waste
heats to provide an efficient method for houseand space heating and reported that the proper
resources utilization in thesense that this ‘‘waste to heat’’ technique is thermodynamically more
usefulthan the current practice of converting natural gas with high exergy contentinto flue gas at
very high temperature and then using it to heat water for spaceheating. In the proposed design, an
integrated (technical and institutional)conceptual design approach has been suggested for a more
robust design.22From the technical side, a high and low-temperature heating system design
isproposed.

Soylemez (2003) has conducted thermo economic optimizationanalysis on heat pump in drying
systems with waste heat recovery andpresented simple algebraic formula for estimating the
optimum operatingconditions of heat pump with auxiliary heating that are used in
dryingapplication.

Soylemez (2005) developed a simple method for estimatingoptimum operating conditions of heat
pump with auxiliary heating that areused in drying application. The optimum operating
temperatures and theoptimum sizes of system components are calculated at which minimum
lifecycle cost occurs for the heat pump driven drying system. The validity of theoptimization
formulation is checked. Heat pump systems used for dryers mustbe designed close to this
optimum point.

Ogulata (2004) suggested the convection-type drying machine inwhich the heat and mass
transfers result from contact of the hot drying airwith humid textile materials to have a
significant energy savings in textiledrying process.

Monte et al (2003) made a case study in a coffee roasting plantdrawn the energy balance of the
roasting process confirmed the feasibility ofheat recuperation from a high temperature source.

Junhong et al (2003) made an experiment on a waste heat recoveryapparatus that utilizes the
truck exhaust gas to heat the bitumen used in roadmaintenance by means of heat transfer oil as
working fluid when en route toroad maintenance destination.23

Roulet et al (2001) studied the real energy recovery with airhandling units from a theoretical
point of view and presents results ofmeasurements on 13 industrial units and found that in the
best three cases, thereal, global heat recovery efficiency was between 60 and 70% for
unitshaving an 80% nominal efficiency. In the three worst cases, the globalefficiency was less
than 10%. For these cases, the heat recovery system usesmore energy than it saves
Wong et al (2010) made an investigation on the potential for showerwater heat recovery from
bathrooms equipped with instantaneous waterheaters in high-rise residential buildings of Hong
Kong. A simple single-passcounter-flow heat exchanger installed horizontally beneath the
shower drain isemployed as a localized heat recovery measure for preheating cold watergoing to
a water heater. The results indicate that 4–15% shower water heatcan be recovered through a 1.5
m long single-pass counter-flow heatexchanger for a drainage pipe of diameter 50 mm.
General objective

the main objective of this project is design of heat exchanger for heating
purpose

Specific objective
Geometry Modeling
Heat exchanger length
Shell inner diameter,
Tube outer diameter,
Tube bundle geometry and pitch
triangular
Number of tubes,
Number of baffles,
Central baffle spacing,
Baffle inclination angle ,

Methodology

Work plan

Budget

Reference