MREN 506 ENERGY USE &

EFFICIENCY ppt 2
ENERGY SAVING OPPORTUNITIES IN VARIOUS INDUSTRIES
(cont’d)
Lecturer: Eng. L. Madiye
E-mail: lmadiye@eng.uz.ac.zw
 3.0 Waste Heat recovery
In many applications it is possible to greatly reduce energy costs by employing some
form of waste heat recovery device. Before investing in such technology it is necessary
to first consider the following issues;
• Is there a suitable waste heat source
• Is there a market or use for the recovered waste heat
• Will the addition of a heat recovery device actually save primary energy or reduce
energy costs
• Will any investment in heat recovery technology be economic
 Waste Heat recovery
If a strategic decision is made to invest in some form of heat
recovery device, then the most logical step is to select the most
appropriate system. There are a wide variety of heat recovery
technologies which can be divided into the following broad
categories;
• Recuperative heat exchangers – two fluids involved in the heat
exchange are separated at all times by a solid barrier
 Waste Heat recovery
• Run-around coils – an independent circulating fluid is used to
transport heat between the hot & cold streams
• Regenerative heat exchangers – hot & cold fluids pass alternately
across a matrix of material
• Heat pumps – a vapour compression cycle is used to transfer heat
between the hot & cold streams
 3.1 Recuperative Heat Exchangers
• The two fluids involved in the heat transfer are separated at all times by a solid barrier. Thus, the heat
transfer mechanisms are convective & radiation.
• Thermal resistance of a heat exchanger can therefore be expressed as;
1 1 1
R = 𝑈 = ℎ + 𝑅𝑤 + ℎ𝑜
+ 𝐹𝑖 + 𝐹𝑜 ………………….(1)
𝑖

Where R is thermal resistance of heat exchanger (𝑚2 𝐾/𝑊)

𝑅𝑤 is the thermal resistance of the separating wall (𝑚2 𝐾/𝑊)
ℎ𝑖 & ℎ𝑜 are the heat transfer coefficients of internal & external surfaces
(W/ 𝑚2 𝐾), 𝐹𝑖 & 𝐹𝑜 are the internal & external fouling factors, 𝑈 is the overall
heat transfer coefficient (W/ 𝑚2 𝐾).
 Recuperative Heat Exchangers
• In short this can be written as;
1 1
= + Fouling factors ……………………(2)
𝑈𝑑𝑖𝑟𝑡𝑦 𝑈𝑐𝑙𝑒𝑎𝑛

• In practice heat exchangers are oversized so that even when fouled their
performance still meets design requirements. The degree of oversizing is
achieved by incorporating fouling factors into the sizing equation.
• Recuperative heat exchangers are the most common type of equipment used
for waste heat recovery.
 Recuperative Heat Exchangers

Widely used types of recuperative heat exchangers;

• Shell & heat tube heat exchanger
• Plate heat exchanger
• Flat plate recuperator
 Heat Exchanger theory

Two most commonly used heat

exchanger configurations are
counterflow & parallel flow
Heat Exchanger configurations
(a) Counterflow heat exchanger
(b) Parallel flow heat exchanger
 4.1 Combine Heat and Power (CHP) Concept

• Generation of electricity in thermal power stations is an extremely wasteful

process from an energy point of view.
• Efficiency for most conventional thermal power stations is in the range 30 –
37 %
• Combined cycle gas turbine stations achieve ≈ 47 % efficiency
• Effectively more than 50 % of the primary energy consumed in the
generation process is wasted as heat energy
 CHP Concept
CHP schemes enable electricity to be generated locally & eliminate much of the
wasted heat which normally occurs in conventional power plants. Through use
of CHP it is possible to:
• Improve national energy efficiency & preserve non-renewable energy
reserves
• Reduce cost of transmission of electrical energy
• Reduce atmospheric pollution due to more efficient fuel conversion.
 CHP Concept
Barriers to widespread use of CHP include:
• CHP plant requires considerable capital expenditure. This requires a full
financial appraisal of future energy demands, fuel prices & maintenance
costs. In the end most organizations resort to conventional power plants they
are familiar with.
• There must be a demand for the heat from any proposed CHP plant.
• Back up plant is often required in CHP installations. This back up plant adds
to capital cost of the installation.
 4.2 CHP System Efficiency

It is possible to illustrate the energy-saving merits of

CHP systems by comparing the primary energy
consumption of a typical micro-CHP plant with that
consumed by a conventional system in which heat is
produced in a boiler & electrical power is purchased
from a utility company.
 4.3 CHP Systems
• CHP systems can range from small micro installations designed to
serve the needs of a single building, to large systems which satisfy
the heating & electrical requirements of whole towns.
• Micro-CHP systems tend to be used when electrical demand does
not exceed 1 MW, while gas turbines are popular on larger
installations, and steam turbines are used on the largest
installations.
 CHP Systems

The following are the CHP systems in use;

1. Internal combustion engines
2. Gas turbines
3. Steam turbines
Schematic diagram of a gas turbine
Schematic diagram of back-pressure steam
turbine
 4.4 Operating and Capital Costs
• Capital costs of CHP plant can be significantly higher than those
for conventional boiler plant. One significant cost comes from the
fact that CHP systems need to be synchronized in parallel with
the local utility so that the CHP unit & the grid can work together
to meet peak site electrical demand.
• However, the operating costs are low as compared to
conventional systems
 4.5 CHP plant sizing strategies
In order to correctly size a CHP installation it is important to obtain
as much accurate energy data as possible. This data includes;
• Monthly electricity & heat energy data in kWh
• Base & peak load demands for both electricity & heat
• Operational characteristics of the particular application
• Unit cost of electricity & gas
 4.6 Economics of CHP

Three cost which dominate economic viability are:

• Capital cost of installation
• Potential hours of operation per year
• Relative costs of bought in electricity or gas