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16 comments
Associate

Join Date: Apr 2013
Posts: 40

Waste Heat to Power

05/09/2013 8:16 AM

We have at our manufacturing facility a substantial amount of waste heat. There are two (2) ammonia crackers which operate 24-7 at around 925°C, two kilns operating at 1500°C (one of which at present operates 24-7), a gas boiler for heat and humidity, and a compressor. Does anyone have any experience or insight regarding the capture of waste heat and using it to produce electricity?

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Pathfinder Tags: CHP waste heat
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Anonymous Poster #1
#1

Re: Waste Heat to Power

05/09/2013 8:26 AM
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Guru

Join Date: Mar 2007
Location: at the beach in Florida
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#2

Re: Waste Heat to Power

05/09/2013 12:15 PM

Well I think you would need a design engineer on site to see if it would be cost effective....You would probably have to convert the heat to steam, which means you would need heat exchangers, probably custom made....

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Guru

Join Date: Apr 2011
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#3

Re: Waste Heat to Power

05/09/2013 12:45 PM

When you wrote:

'..a gas boiler for heat and humidity...'

.

What exactly do you mean? Are you talking about heating the air in the work spaces?

.

The reason I ask is because instead of turning the waste heat into electricity, sometimes a better idea is to simply use the waste heat without converting, thereby reducing some fuel costs and operation cost (and additional heat) of equipment used currently.

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Associate

Join Date: Apr 2013
Posts: 40
#5
In reply to #3

Re: Waste Heat to Power

05/09/2013 1:04 PM

We do currently duct the waste heat from the air compressor into the work areas. That became a viable option for us when we upgraded and relocated the compressor. The boiler does produce the heat and humidity necessary to regulate temp and moisture. We have several processes that rely on a specific humidity in the air.

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Join Date: Mar 2010
Location: In the pool because it is too hot.
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#4

Re: Waste Heat to Power

05/09/2013 1:00 PM

Where you are and you climate is very important before making any conclusions. Besides that you need to give us a "book" of information before getting answers that will help.

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#6

Re: Waste Heat to Power

05/09/2013 3:17 PM

In both cracking and the kiln you are using energy to create the heat for the processes. If you have that much heat coming from the process. Would it not be more cost effective to better insulate to reduce the lost heat. Reducing the energy consumption. In trying to reclaim the heat that's being lost you will never see the benefits that you would get if you never had the waste to begin with.

The only area I could see some benefit is the cooling of the product from the kiln. Not knowing what that product is I don't know if it possible.

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Associate

Join Date: Apr 2013
Posts: 40
#11
In reply to #6

Re: Waste Heat to Power

05/10/2013 7:49 AM

Better insulation definitely merits consideration. Thanks for the suggestion ozzb.

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Participant

Join Date: Nov 2012
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#7

Re: Waste Heat to Power

05/09/2013 11:28 PM

Dear,

Lot can be done with this waste of energy.

Do communicate to me.

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Guru

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#8
In reply to #7

Re: Waste Heat to Power

05/09/2013 11:42 PM

You must love spam.

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Active Contributor

Join Date: Jan 2013
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#9

Re: Waste Heat to Power

05/10/2013 1:36 AM

Talk to these guys, they are one of the best in the world at waste heat recovery and cogeneration plants.The GC Broach Company: http://www.broach.com

Ask to speak with Brian Broach.

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Associate

Join Date: Apr 2013
Posts: 40
#10
In reply to #9

Re: Waste Heat to Power

05/10/2013 7:47 AM

Thank you for the resource Horizon3. We are just in the beginning stages of exploring a potential opportunity with our waste heat recovery. We want to learn more about WHR and its potential uses before making a decision on its viability as an option for us.

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Power-User

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#12

Re: Waste Heat to Power

05/10/2013 8:09 AM

How about waste heat of Kilns be utilized in Ammonia crackers and then you have one waste heat component of Ammonia crackers only, to reduce your capital investment of waste heat recovery. Secondly look out for using the steam generated for humidity generation too. So this portion need not be utilized for Power generation. This will further reduce your capital cost.

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Active Contributor

Join Date: Feb 2011
Location: Located in NY - Territory is North America
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#13

Re: Waste Heat to Power

05/10/2013 8:25 AM

You have raised many questions. I am the senior project manager with Chant Power, Inc. & Chant International. We are an engineering, construction and construction management group specializing in energy generation & transmission.

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Power-User

Join Date: Mar 2009
Location: Southern IN.
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#14

Re: Waste Heat to Power

05/10/2013 8:29 AM

This is a good question of how to use the waste heat! The best waste heat to machine is part of some thing that most people don't think possible, With that said is the waste heat at one point of your structure, like a central heat room for all the workings.

The shape of the structure & height above the main exhaust is crussual. A cone shape structure can be built over the plants roof, Not touching structure but open all around so as to help cool air intake( this will help with roof maintenance) cone top should be 50 - 60ft at smallest point. The working height for maxim wind speeds should be 100-150ft above the ground. Now the heat and natural wind will power a regular generator. The fans are jet type not blade counter rotation driving hydraulic pumps with accumulators, for backup.

The best information can be seen on the energy site all 1 word renewablethermalwindpower.com

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Guru

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#15

Re: Waste Heat to Power

05/10/2013 9:08 AM

Your waste heat is apparently a higher quality heat than most boiler plants operate from. Therefore, some care will have to be made that when pulling off the waste heat, you may need to attemperate this with a slight water spray (wastes a lot of water, not so good), or simply use external air blending. From the varied sources in your plant, all at different temperatures, you should really talk to a design engineering firm with extensive HRSG experience, and you will undoubtedly need a triple drum HRSG (high pressure, intermediate pressure, low pressure). The steam turbine used to employ the steam generated will need to be tailored specifically to your situation to best utilize the steam available to produce the most Megawatts. Another issue is you must come up with a contract to sell the electricity or plan to consume all of it internally to your operation.

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Power-User

Join Date: Mar 2009
Location: Southern IN.
Posts: 140
#16
In reply to #15

Re: Waste Heat to Power

05/13/2013 7:45 AM

James! you are partly right when you say simply use external air from the base of the cone shape structure for fresh air intake to blend with the heat as it raises up in the vortex chamber, By doing this you wouldn't have to spray water to cool what you need to be hot or to use steam, Waste heat is the driving force as it mixes with natural wind to drive the hydraulic pumps from kinetic thermal wind to drive the generators.

The cost to install this structure is only1/4 of cost they already have the rest in place.

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Users who posted comments:

Anonymous Poster (1); Dhiren Gandhi (1); dvmdsc (1); Gene Schoonmakerfranczek (1); Guest1947 (1); Horizon3 (1); James Stewart (1); jcwelch111 (3); kennynabb6 (2); ozzb (1); SolarEagle (1); truth is not a compromise (2)

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