Industrial Waste Heat Recovery

Industrial Waste Heat Recovery Industrial Energy RoundTable Kathey Ferland Project Manager Texas Industries of the Future kferland@mail.utexas.edu Riyaz Papar, PE, CEM Director, Energy Assets & Optimization Hudson Technologies Company rpapar@hudsontech.com August 15, 2007

Welcome & Introductions Sponsor US Department of Energy Office of Energy Efficiency and Renewable Energy, under a contract with the State Energy Conservation Office

Agenda Welcome and Introductions Industrial Waste Heat Recovery Presentation Concepts & questions Some ideas and technology examples Sensible preheating Condensing economizers Fumes to fuel / Power generation Mechanical vapor recompression or Thermal compression Industrial heat pumps Chilled water / Refrigeration Challenges Round table discussion

DOE Technology RoadMap www.eere.energy.gov/industry/energy_systems/pdfs/reduction_roadmap.pdf

Concepts & Questions

Concepts & Questions

Concepts & Questions What is waste heat recovery? Industry dependent Glass, metals industry - 750 F PetroChemicals & refining - 300 F Food & beverage industry - 180 F Buildings and facilities - 140 F How much is it? Heat content MMBtuh Product yield What is it (substance)? Contaminated waste steam from fractionating / stripping process Waste gases from boilers, furnaces, vents, flares, etc. Can it be recovered? Can it be used?

Concepts & Questions Where is it? Utility plant Process unit What is the environment? Sensible Latent Acidic, etc. Direct / Indirect contact When is it available? Continuous Batch mode

Ideas & Technologies Sensible preheating Condensing economizers Fumes to fuel / Power generation Mechanical vapor recompression or Thermal compression Industrial heat pumps Chilled water / Refrigeration Other ideas from the RoundTable group..

Sensible Preheating Most common form found in the industry Utility side BFW preheat Blowdown / Makeup heat recovery Combustion air preheat Compressed air heat recovery Other.. Process side typically some level of pinch or optimization is done and so the process is highly integrated Preheat reaction feed streams Preheat process water Other..

VOC Waste Heat Recovery Freescale Semiconductor Background/Strategy: Recover heat from VOC exhaust abatement combustion system by installation of heat exchanger on combustion gases to transfer energy to the site hot water supply system, reducing hot water system natural gas consumption by 12,000 MMBtu annually

VOC Heat Recovery System PP1 Hot Water boilers MAU MAU closed MAU MAU MAU MAU DP1 V2 V1 PP : pump V : automatic valve PP3 PP2 D : automatic damper DP2 MAU: make up air unit : D: flowmeter T: Temperature sensor V5 F P: Pressure sensor VOC Exhaust Air Outlet (combustion gases) Air Température : 350 C Air Flow : 11000 m3/h T2 P1 V3 D1 Heat exchangeur 400 kw D3 V4 D2 T1 water flow : 60m3/h water T : 40 to 60 C

Condensing Economizers Very predominant in Europe Relatively recent in the US less than 5 years in market but it has picked up now Two types Direct contact Closed loop Industrial applications are seeing simple paybacks: 6 months - 2 years Several installations, manufacturers, gas companies

Condensing Economizers

Condensing Economizers

Condensing Economizers

SuperBoiler? Not a bigger boiler but a better boiler! Higher energy efficiency - more than 95% HHV Super-low emissions - down to 2 ppm NOx and 5 ppm CO Smaller and lighter - reduce size and weight by 50 percent Competitive performance Cost-effective Energy Efficiency, % NOx, ppmv 100 80 60 40 20 0 Typical industrial boiler State of the art* 2020 Super Boiler Efficiency Emissions Footprint 25 20 15 10 5 0 Footprint, sq ft per klb/h steam * Not all in the same boiler

Emerging Technology: SuperBoiler Project Description: Gas-fired package boiler using innovative concepts in burner, heat transfer, heat recovery & control Licensed to Cleaver-Brooks Technical Objectives 94% efficiency (from 70-83%) <5 ppm NOx (from 30-100 ppm) Status Field Demonstration No. 1 (Alabama) completed successfully Field Demonstration No. 2 (California): Fabrication of 300-HP two-stage boiler underway and beginning pre-testing at Cleaver-Brooks manufacturing facility

Fumes to Fuel Technology Ford Motor Company & DTE Energy Partnership VOC concentrator applicable to chemical plants Solid Oxide Fuel Cell

Fumes to Fuel Technology

MVR / Thermal Compression Main intent Recover latent energy of low pressure steam Mechanical Vapor Recompression Boost the vented steam pressure via an electric motor driven compressor Based on compression ratio, energy used by compressor could be only 10-15% of boiler energy Thermal Compression Use of a converging-diverging nozzle Needs motive steam Called an Ejector when used to create vacuum

Industrial Heat Pumps http://www1.eere.energy.gov/industry/bestpractices/pdfs/heatpump.pdf

Heat from Cooling Towers Cooling Towers 83 F Min 60 F 2,500 gpm 120 F 72 F 650gpm 100 F 6,500MBH Heat Pump Chillers 82 F 92 F 550gpm Average COP 5.5 to 6.5 1,000TR 54 F 44 F 1,000TR Courtesy: York International / Johnson Controls

Heat from Chilled Water Hot water loop Boiler 130 F 155 F Heat Pump 50 F Variable F Chilled water loop Chillers Courtesy: York International / Johnson Controls

Heat Pumps YS CYK To 140 F / 60 C 5,600MBH / 1,650kW YK To 155 F / 68 C 38,000MBH / 11,000kW Titan From condenser water only To 155 F / 68 C 30,000MBH / 8,800kW Courtesy: York International / Johnson Controls To 170 F / 77 C 74,000MBH / 22,000kW

Thermally Activated Technology CHP Output Efficiency is generally higher for Combustion Turbine based CHP system than IC Engine based systems Generating Technology Thermal Technology (Chiller) Electrical Output (MW) Thermal Electric Ratio (TR/kW) CHP Output efficiency, HHV Large Combustion Turbine Steam Turbine >2.5 0.6 77% Small Combustion Turbine Double Effect Absorption 1 to 2.5 0.7 69% Microturbine Double Effect Absorption 0.25 to 0.5 0.5 60% Reciprocating Engine Double Effect Absorption 1.5 to 5 0.2 50% Reciprocating Engine Single Effect Absorption 0.25 to 5 0.3 58% Microturbine Single Effect Absorption 0.25 to 0.5 0.4 44% CHP Output Efficiency = (Total busbar kw + Cooling converted directly to kw) / Fuel Input (HHV) Courtesy: York International / Johnson Controls

Thermally-Activated HVAC Technologies Distributed Generation Technologies Thermally-Activated HVAC Technologies 800ºF 600ºF Gas-turbine Steam Turbine Centrifugal Chiller 360ºF Micro-turbine 180ºF Double-Effect Absorption Chiller I.C. Engine Single-Effect Absorption Chiller Courtesy: York International / Johnson Controls

Combined Heat & Power <2MW Exhaust Heat Recovery Jacket Heat Recovery Generator Gas Engine Gas Courtesy: York International / Johnson Controls

Waste Heat fired Absorption Chillers LiBr H2O machines Available from all the major US and international chiller manufacturers Single effect machines used with Low pressure steam (< 15 psig) Hot water (> 180F) Direct fired exhaust gases Relatively, maintenance free Provide chilled water only since water is the refrigerant They have a wide size range strong function of economies of scale Relatively flat performance curve COP ~ 0.5 Footprint could become an issue Higher $/ton compared to mechanical vapor compression

Waste Heat fired Absorption Chillers Courtesy: York International / Johnson Controls

Waste Heat fired Absorption Chillers Commercially available LiBr/water machines Provide chilled water only Can use waste heat, low pressure steam http://www.ornl.gov/sci/engineering_science_technology/cooling_heating_power/pdf/ishpc-095-2005.pdf

Instant CHP The ICHM The ICHM is a pre-fabricated Integrated Cooling & Heating Module The ICHM includes an absorber, load heat exchanger, cooling tower, condenser pump, system controls, pipe, valves and fittings in an outdoor enclosure The ICHM provides simultaneous heating and cooling for maximum load factor Designed for CHP applications with specific engines generator models Saves 30% on installed costs versus site constructed systems Saves on engineering time and mistakes Courtesy: York International / Johnson Controls

Refrigeration From Engine Waste Heat Courtesy: Energy Concepts Company 160 tons refrigeration at 25F waste heat from 830 kw gas-fired reciprocating engine uses both exhaust heat and jacket heat 8 ft by 8 ft footprint, 9000 pounds

Waste Heat Refrigeration Installed in 1997 Recovers 200 barrels LPG per day Double lift cycle, -25 o F from 280 o F liquid stream Courtesy: Energy Concepts Company

Ammonia Absorption Refrigeration At comparable production levels, cost approximates vapor compression $/ton Custom units start at $1000 per ton Subzero temperature industrial systems show cost advantage over mechanical vapor compression Ammonia absorption is built to industrial standards. This means that AA can be directly integrated into the process, which makes a lot more things possible. More attractive paybacks (1 to 3 years) are obtained with debottleneck applications and increased recovery applications.

Adsorption Chiller HIJC USA, INC.

Adsorption Chiller HIJC USA, INC.

Challenges Diverse industrial processes and site specific conditions Energy price and supply uncertainties Regulatory uncertainties Materials durability Metallurgy Equipment fouling Reliability Safety Economic feasibility

Other Comments Mechanical vapor recompression and thermal recompression to reuse the waste heat in distillation overhead as a heat source for reboiling Useful applications for waste steam at low pressures, less than 40 psig Understand where recovery of low level heat has proven cost effective

RoundTable Discussion