Waste Heat Recovery System Engineering Essay

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Waste heat recovery system is the process of utilizing waste heat that is being produced in various heating processes. There is enormous heat that is being wasted by industries which affects the efficiency of the industry to a greater extent than any other factors. So, there is an inevitable need to solve this problem and make sure that the efficiency of the industry is increased. High temperature heat recovery potential is available in many industries. High temperature waste heat available can be utilized for generating power, heating water & air, increasing process temperature etc. Considering the acute shortage of power, this ready source can prove a boon to the industry in more than one way. This project is carried out at Nava Bharat Ventures Limited (NBVL), Paloncha, and Khammam District in utilization of waste heat available from Submerged Electric Arc Furnace (SEAF) fuel gases by installing a Double pass heat exchanger (LPHX – Low Pressure Heat Exchanger and HPHX – High Pressure Heat Exchanger) in fuel gas path. Generally Main Condensate & Feed Water in Power Plant is heated in LP & HP heaters of Turbine regeneration cycle by drawing steam from Steam Turbine extractions.

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West Virginia Alloys, a silicon manufacturer, will install a waste heat recovery system that will generate 45 megawatts of electrical power. The company only uses 120 megawatts right now. (Put another way, the company only really needs 75 megawatts for its operations and is currently burning off 45 megawatts.) To date, the big challenge has been cost. Most industrial-scale waste heat projects cost between $5 and $50 million. That’s too high for most to pay out of capital budgets and too low for a public financing project. “There’s a huge Goldilocks problem,” he said. To get around this, RED pays for any waste heat recovery system it installs and then gets paid for energy savings under long-term contracts. Goldilocks problem is nothing but finding the appropriate solution for the problem.

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Chapter 5: CONCLUSIONS . The objective of this project was to design a Waste Heat Recovery System (WHRS) for Nava Bharat Ventures Limited. The existing system was examined and found 1.25 x 107 kCal/hr of waste energy is reject to the environment from Sub – merged Electric Arc Furnace (SEAF). When calculating energy savings and payback periods for heat recovery units, it is important to compare heat recovery with the current source of energy for generating thermal energy, which may be a low-price fossil fuel such as natural gas. The aim of installing a new energy recovery system at Nava Bharat Ventures Ltd was to be able to reduce fuel cost and increase Steam Turbine heat rate caused by heat being lost to the environment. Simultaneously, the GDP ID fan power consumption will reduce, life of GCP bags is increased by reducing the gas temperature at GCP inlet and thermal pollution also will reduce. A Double pass Heat exchanger was selected and designed to recover heat from exit fuel gases of SEAF system and heat the Feed Water and Main Condensate by utilizing the waste energy available in fuel gas. The main focus of this project was to reduce the cost of energy bills by reducing the amount of fuel used to heat the facility.

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