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Heat Recovery System

Objective- To develop a Heat Recovery System for 3 Tonne Furnace.


Basic Working Principle- A large amount of heat is wasted in the form of Exhaust Gas generated at
the furnace due to the combustion of fuel and air in the combustion chamber. This heat is being
directed to the chimney without utilizing the remaining heat content which can be used to either
preheat water in the boiler or can be used to heat the water that can be sent directly to the STP. The
efficiency of the own plant increases noticeably by this technology, whereby expensive primary
energy can be saved. In this way, the existing residual heat can be significantly reduced by using it for
recovery.
Further, this exhaust gas can be used as turbocharger to preheat the air fuel mixture in the Exogas
plant, where it can be used to preheat the air to increase the efficiency of the ExoGas plant.
Methods and Ideas-
1.We can design a recuperator type of Heat Exchanger which requires a well for water storage and
regulation whose wall lining should be coated so that no leakage occurs. After that exhaust gas pipe
line is passed through that well filled with water .Due to heat transfer water get heat up and can be
sent to STP area with the help of pump.
2.We can also design a pipe line network from furnace to boiler such that we can directly send that
exhaust gas heat to the boiler where it can be used in place of PNG gas. Advantage of this system is
existing boiler and STP network can be used without much more new installation and expense.
3.We can directly purchase a suitable type of heat exchange according to our parameter by consulting
a reputed heat exchanger manufacturer company.
NOTE-These all are brief ideas and required more brainstorming and further most we required
an expert person who has good experience in thermal science engineering to assist us through
out the project.
As because considerable amount of heat is lost from furnace exhaust so this project has a lot of
scope , ROI can also be good. Also this process is a little bit complicated as because from
technical aspect it has many things to consider if we want to make it best working system so it
requires advise of experienced person and some additional time to execute.
Data Collected-
Exact Available Data-
Return water from STP temp.- 90 ℃
Water outlet temp. from boiler- 105-110 ℃
Diameter of Suction & Discharge line from boiler- 4”
Diameter of pipe in STP tanks- 3.75”
Air Fuel ratio- 6:1
Calorific value of PNG- 39748 KJ/Kg-K

Approx. or Assumed Data-

Mass flow rate of STP water- 100L/hr


Exhaust Gas Temp. – 500-700 ℃ (no monitoring system available in present)
Preliminary Calculation-
Q=Heat required to take water from 20℃ to 120℃ in a heat exchanger(KW)
m’ = mass flowrate of water (kg/s)
Cpwl & Cpws= Specific heat of water in liquid and steam(KJ/Kg-k)
L= Latent Heat of Vapourization
Q=m’*[Cpwl*(T2-T1)+ L+ Cpws*(T4-T3)]
Q=100/3600*[4.184*80+ 2260+ 1.996*20]
Q= 73KW
This is the heat required to take water from 20℃ to 120℃ in a heat exchanger once but for rotation of
water in the STP which takes place between 90 and 110 , the following amount of heat is required,
Q=100/3600*[4.184*10+2260+1.996*20]
Q=65KW
How is excess air calculated?

Excess Air = 100 x (20.9%) / (20.9% -O2m%) - 100%


Where O2 m% = The measured value of oxygen in the exhaust.

Examples:

When O2m% = 0% Then excess air = 0


When O2m% = 5% Then: excess air = 100 x (20.9%) / (20.9%-5%) - 100%
excess air = 100 x (20.9%) / (15.9%) - 100%
excess air = 100 x (1.31) - 100%

excess air = 31%

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