RoundTable 0807

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

© Hudson Technologies
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

¾ Concepts & questions
¾ Some ideas and technology examples
9 Sensible preheating
9 Condensing economizers
9 Fumes to fuel / Power generation
9 Mechanical vapor recompression or Thermal compression
9 Industrial heat pumps
9 Chilled water / Refrigeration
¾ Challenges
Round table discussion

DOE Technology RoadMap
www.eere.energy.gov/industry/energy_systems/pdfs/reduction_roadmap.pdf
Concepts & Questions
What is waste heat recovery?

¾ Industry dependent
9 Glass, metals industry - 750°F
9 PetroChemicals & refining - 300°F
9 Food & beverage industry - 180°F
9 Buildings and facilities - 140°F
How much is it?

¾ Heat content – MMBtuh
¾ Product yield
What is it (substance)?
¾ Contaminated waste steam from fractionating / stripping process
¾ Waste gases from boilers, furnaces, vents, flares, etc.
Can it be recovered?
Can it be used?
Where is it?
¾ Utility plant
¾ Process unit
What is the environment?

¾ Sensible
¾ Latent
¾ Acidic, etc.
¾ Direct / Indirect contact
When is it available?
¾ Continuous
¾ 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
¾ BFW preheat
¾ Blowdown / Makeup heat recovery
¾ Combustion air preheat
¾ Compressed air heat recovery
¾ Other…..
Process side – typically some level of pinch or optimization

is done and so the process is highly integrated
¾ Preheat reaction feed streams
¾ Preheat process water
¾ 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
MAU MAU MAU MAU MAU

boilers MAU DP1
V2
closed
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
V3 V4 T1
T2
Heat exchangeur water flow : 60m3/h
V OC Exhaust D1 400 kw D2 water T : 40 to 60°C
A ir O utlet P1
(com bustion gases)
Air Température : 350°C
Air Flow : 11000 m3/h
D3
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
¾ Direct contact
¾ Closed loop
Industrial applications are seeing simple paybacks: 6 months

- 2 years
Several installations, manufacturers, gas companies
SuperBoiler?
100 25
Not a bigger boiler
Footprint, sq ft per klb/h steam

80 20
but a better boiler!
Energy Efficiency, %
Higher energy efficiency -
NOx, ppmv
¾ 60 15
more than 95% HHV
¾ Super-low emissions - 40 10
down to 2 ppm NOx
and 5 ppm CO
20 5
¾ Smaller and lighter -
reduce size and weight by
50 percent 0 0
Typical State of the 2020 Super
¾ Competitive performance industrial art* Boiler
¾ Cost-effective boiler
Efficiency Emissions Footprint
* Not all in the same boiler
Emerging Technology: SuperBoiler
Project Description:
¾ Gas-fired package boiler using
innovative concepts in burner, heat
transfer, heat recovery & control
¾ Licensed to Cleaver-Brooks
Technical Objectives
¾ 94% efficiency (from 70-83%)
¾ <5 ppm NOx (from 30-100 ppm)
Status
¾ Field Demonstration No. 1 (Alabama) completed successfully
¾ 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
¾ Boost the vented steam pressure via an electric motor
driven compressor
¾ Based on compression ratio, energy used by compressor
could be only 10-15% of boiler energy
Thermal Compression
¾ Use of a converging-diverging nozzle
¾ Needs motive steam
¾ 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
650gpm
120°F 100°F
Cooling 6,500MBH
Towers
2,500 Heat Pump
gpm
83°F
72°F
Min 60°F
82°F 92°F
550gpm
Chillers Average COP 5.5 to 6.5
1,000TR 1,000TR
54°F 44°F
Courtesy: York International / Johnson Controls © Hudson Technologies

Heat from Chilled Water
Hot water loop
Boiler
130°F 155°F
Heat Pump
50°F Variable °F
Chillers
Chilled water loop

Heat Pumps
YS CYK
To 140°F / 60°C To 155°F / 68°C

5,600MBH / 1,650kW 38,000MBH / 11,000kW
YK Titan
From
condenser
water only
To 155°F / 68°C To 170°F / 77°C

30,000MBH / 8,800kW 74,000MBH / 22,000kW
Thermally Activated Technology
CHP Output Efficiency is generally higher for Combustion

Turbine based CHP system than IC Engine based systems
Thermal CHP
Electrical
Thermal Technology Electric Output
Generating Technology Output
(Chiller) Ratio efficiency,
(MW)
(TR/kW) 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)

Thermally-Activated HVAC
Technologies
Distributed Generation Thermally-Activated HVAC

Technologies Technologies
800ºF
600ºF
Gas-turbine Steam Turbine

Centrifugal Chiller
360ºF
Double-Effect
Absorption
Chiller
Micro-turbine
180ºF
Single-Effect
I.C. Engine Absorption Chiller

Combined Heat & Power <2MW
Exhaust Heat Recovery
Jacket Heat Recovery
Generator
Gas Engine
Gas

Waste Heat fired Absorption Chillers
LiBr – H2O machines

Available from all the major US and international chiller
manufacturers
Single effect machines used with
¾ Low pressure steam (< 15 psig)
¾ Hot water (> 180F)
¾ 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

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
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, -25oF from 280oF 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

RoundTable 0807

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Industrial Waste Heat Recovery

Industrial Energy RoundTable

Riyaz Papar, PE, CEM

August 15, 2007

 Welcome and Introductions

 Industrial Waste Heat Recovery Presentation

 Round table discussion

 What is waste heat recovery?

 How much is it?

 What is the environment?

 Fumes to fuel / Power generation

 Mechanical vapor recompression or Thermal compression

 Industrial heat pumps

 Chilled water / Refrigeration

 Other ideas from the RoundTable group…..

 Most common form found in the industry

 Process side – typically some level of pinch or optimization

PP1 Hot Water

MAU MAU MAU MAU MAU

D : automatic damper DP2

 Very predominant in Europe

 Relatively recent in the US – less than 5 years in market –

 Industrial applications are seeing simple paybacks: 6 months

 Several installations, manufacturers, gas companies

Not a bigger boiler

Footprint, sq ft per klb/h steam

Efficiency Emissions Footprint

* Not all in the same boiler

 Ford Motor Company & DTE Energy Partnership

 Main intent – Recover latent energy of low pressure

Chillers Average COP 5.5 to 6.5

Courtesy: York International / Johnson Controls © Hudson Technologies

Hot water loop

Courtesy: York International / Johnson Controls © Hudson Technologies

To 140°F / 60°C To 155°F / 68°C

To 155°F / 68°C To 170°F / 77°C

 CHP Output Efficiency is generally higher for Combustion

Courtesy: York International / Johnson Controls © Hudson Technologies

Distributed Generation Thermally-Activated HVAC

Gas-turbine Steam Turbine

Courtesy: York International / Johnson Controls © Hudson Technologies

Exhaust Heat Recovery

Jacket Heat Recovery

Courtesy: York International / Johnson Controls © Hudson Technologies

 LiBr – H2O machines

Courtesy: York International / Johnson Controls © Hudson Technologies

 Commercially available – LiBr/water machines

 Saves 30% on installed costs

 Saves on engineering time and

Courtesy: Energy Concepts Company

 160 tons refrigeration at 25F

Courtesy: Energy Concepts Company

 At comparable production levels, cost approximates vapor

 Custom units start at $1000 per ton

 Subzero temperature industrial systems show cost advantage

 Ammonia absorption is built to industrial standards. This

 More attractive paybacks (1 to 3 years) are obtained with

HIJC USA, INC.

HIJC USA, INC.

 Diverse industrial processes and site specific conditions

 Energy price and supply uncertainties

 Materials durability – Metallurgy

Welcome and Introductions

Industrial Waste Heat Recovery Presentation

Round table discussion

What is waste heat recovery?

How much is it?

What is the environment?

Fumes to fuel / Power generation

Mechanical vapor recompression or Thermal compression

Industrial heat pumps

Chilled water / Refrigeration

Other ideas from the RoundTable group…..

Most common form found in the industry

Process side – typically some level of pinch or optimization

Very predominant in Europe

Relatively recent in the US – less than 5 years in market –

Industrial applications are seeing simple paybacks: 6 months

Several installations, manufacturers, gas companies

Ford Motor Company & DTE Energy Partnership

Main intent – Recover latent energy of low pressure

CHP Output Efficiency is generally higher for Combustion

LiBr – H2O machines

Commercially available – LiBr/water machines

Saves 30% on installed costs

Saves on engineering time and

160 tons refrigeration at 25F

At comparable production levels, cost approximates vapor

Custom units start at $1000 per ton

Subzero temperature industrial systems show cost advantage

Ammonia absorption is built to industrial standards. This

More attractive paybacks (1 to 3 years) are obtained with

Diverse industrial processes and site specific conditions

Energy price and supply uncertainties

Materials durability – Metallurgy

Mechanical vapor recompression and thermal

Useful applications for waste steam at low

Understand where recovery of low level heat has