Equipment Description:Heat Recovery
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In times of high fuel prices and growing concern about carbon/greenhouse gas emissions, process industries can no longer afford to waste energy. Optimising heat recovery is an important element of waste heat minimisation. Some heat recovery projects are simple, but in many cases it is not obvious how to achieve the most cost effective outcome for the site as a whole; a number of key questions may need to be addressed (see diagram). Heat recovery can bring substantial energy and emissions savings, often with an excellent return on investment. However, a systematic approach is needed to realise the full potential. |
Process Integration: Pinch Analysis: Heat sinks or Cold streams: Flows which need to be heated Heat sources or Hot streams: Flows which are available and/or need to be cooled Heat Recovery: Reuse of heat within a building/process/site which would otherwise have been lost to the environment Thermal Utilities: Systems for supplying heat to or removing it from a building/process/site, eg boilers, steam distribution, combined heat and power, cooling water systems/towers, refrigeration systems. Combined heat and power: Where (waste) heat from power generation is usefully recovered for another purpose. CHP: Abbreviation for Combined Heat and Power |
 Image © HRC Consultants Ltd |
Tips to optimise heat recovery:- Identify the heat sources and sinks: It is worth creating schematic flow diagrams to understand the heat flows. Existing flowsheets are seldom suitable. Quantify heat sources and sinks: Consistent temperature and heat flow data are necessary. Measurements should be reconciled by heat and material balance. Calculate how much heat recovery is possible: For all but the simplest sites Pinch analysis is usually the best way to do this. Conceptual design and optimisation of projects: It is essential to heat exchange the right heat sources and sinks in the right sequence. Pinch methodology is again relevant. Optimise the projects: Once the basic recovery configuration is defined, trade off between savings and capital cost can be resolved. A heat and material balance model is useful here too. Economic feasibility study: Heat recovery should be reviewed in the same way as any other engineering project. Detailed engineering and implementation: The project team must understand both the heat recovery concepts and the constraints of the process itself. |
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