{"id":36635,"date":"2019-10-31T22:12:47","date_gmt":"2019-10-31T19:12:47","guid":{"rendered":"https:\/\/prohoster.info\/blog\/utilizatsiya-tepla-dymovyh-gazov-ekologiya-s-vygodoj\/"},"modified":"2019-10-31T22:12:47","modified_gmt":"2019-10-31T19:12:47","slug":"utilizatsiya-tepla-dymovyh-gazov-ekologiya-s-vygodoj","status":"publish","type":"post","link":"https:\/\/prohoster.info\/en\/blog\/news\/utilizatsiya-tepla-dymovyh-gazov-ekologiya-s-vygodoj","title":{"rendered":"Utilization of Flue Gas Heat: Ecology for Profit","gt_translate_keys":[{"key":"rendered","format":"text"}]},"content":{"rendered":"<p>In search of ways to enhance the efficiency of energy sector enterprises, as well as other industrial facilities that use equipment burning fossil fuels (steam, hot water boilers, technological furnaces, etc.), the issue of utilizing the potential of flue gases is not always a primary concern.<\/p>\n<p>Meanwhile, relying on existing calculation standards developed decades ago and established criteria for selecting key performance indicators for such equipment, operating organizations lose money by literally allowing it to escape through the chimney, simultaneously worsening the environmental situation on a global scale.<\/p>\n<p>If, like the team &#171;<noindex><a rel=\"nofollow\" href=\"http:\/\/1-engineer.ru\/\">First Engineer<\/a><\/noindex>&#171;, you believe it is wrong to miss the opportunity to care for the environment and the health of your city's residents while benefiting your company's budget, read the article on how to turn exhaust gases into an energy resource.\u00a0\u00a0<\/p>\n<p><img decoding=\"async\" alt=\"Utilization of Flue Gas Heat: Ecology for Profit\" src=\"\/wp-content\/uploads\/2019\/07\/0be3b38d5840ba0d3b7d71880b2ff28e.jpg\" style=\"display:block;margin: 0 auto;\" \/><noindex><a rel=\"nofollow\" name=\"habracut\"><\/a><\/noindex><\/p>\n<h2>Exploring Standards<\/h2>\n<p>\nA key parameter that defines the efficiency of a boiler unit is the temperature of the outgoing gases. The heat lost with the outgoing gases constitutes a significant portion of all thermal losses (along with losses from chemical and mechanical fuel combustion inefficiencies, losses from the physical heat of ash, and heat leakage into the environment due to external cooling). These losses have a decisive impact on the cost-effectiveness of the boiler's operation, lowering its efficiency. Hence, we understand that the lower the temperature of the flue gases, the higher the boiler's efficiency.<\/p>\n<p>The optimal temperature of outgoing gases for different types of fuel and boiler operating parameters is determined based on techno-economic calculations at the very early stages of its design. At the same time, the most beneficial use of the heat from outgoing gases is traditionally achieved by increasing the size of the convective heating surfaces and developing downstream surfaces such as water economizers and regenerative air preheaters.<\/p>\n<p>However, even with the implementation of technologies and equipment for the most complete heat utilization, the temperature of the outgoing gases according to current regulatory documentation must remain within the range:<\/p>\n<ul>\n<li>120-180 \u00b0C for solid fuel boilers (depending on the fuel moisture and operational parameters of the boiler),<\/li>\n<li>120-160 \u00b0C for heavy fuel oil boilers (depending on the sulfur content),<\/li>\n<li>120-130 \u00b0C for natural gas boilers.<\/li>\n<\/ul>\n<p>\nThe specified values take into account environmental safety factors, but primarily focus on the requirements for the performance and durability of the equipment.<\/p>\n<p>Thus, the minimum threshold is set in such a way as to exclude the risk of condensate formation in the convective part of the boiler and downstream (in the flue ducts and chimney). However, to prevent corrosion, it is not necessary to sacrifice the heat that is released into the atmosphere instead of doing useful work.<\/p>\n<p><img decoding=\"async\" alt=\"Utilization of Flue Gas Heat: Ecology for Profit\" src=\"\/wp-content\/uploads\/2019\/07\/c7ccb20ee5145c228f8270774363b490.jpg\" style=\"display:block;margin: 0 auto;\" \/><\/p>\n<h2>Corrosion. We exclude risks<\/h2>\n<p>\nThere's no denying that corrosion is an unpleasant phenomenon that can jeopardize the safe operation of a boiler installation and significantly reduce its intended lifespan.<\/p>\n<p>When flue gases are cooled to the dew point temperature and below, condensation of water vapor occurs, along with which NOx and SOx compounds change to a liquid state, which, reacting with water, form acids that have a destructive effect on the internal surfaces of the boiler. Depending on the type of fuel being burned, the acid dew point temperature and the composition of the acids that form as condensate can vary. Nevertheless, the result is the same \u2013 corrosion.<\/p>\n<p>The exhaust gases from boilers running on natural gas mainly consist of the following combustion products: water vapor (H2O), carbon dioxide (CO2), carbon monoxide (CO), and unburned hydrocarbon compounds CnHm (the latter two appear when the fuel is incompletely burned, when the combustion regime is not properly tuned).<\/p>\n<p>Since atmospheric air contains a large amount of nitrogen, nitrogen oxides NO and NO2, collectively referred to as NOx, also appear in the combustion products, which adversely affect the environment and human health. When combined with water, nitrogen oxides form corrosion-active nitric acid.<\/p>\n<p>When burning fuel oil and coal, sulfur oxides, referred to as SOx, are produced in the combustion products. Their negative impact on the environment has been widely studied and is not in doubt. The acidic condensate formed from the interaction with water causes sulfuric corrosion of heat transfer surfaces.<\/p>\n<p>Traditionally, the temperature of the exhaust gases, as previously shown, is chosen to protect the equipment from acid deposits on the heating surfaces of the boiler. Moreover, the gas temperature should ensure the condensation of NOx and SOx outside the flue gas path to protect both the boiler itself and the flue ducts with the chimney from corrosive processes. Of course, there are certain regulations limiting the permissible concentrations of nitrogen and sulfur oxide emissions, but this does not negate the accumulation of these combustion products in the Earth's atmosphere and their deposition as acid rains on its surface.<\/p>\n<p>The sulfur contained in fuel oil and coal, along with the carryover of unburned solid fuel particles (including ash), imposes additional requirements for flue gas cleaning. The use of gas cleaning systems significantly increases the cost and complexity of flue gas heat recovery processes, making such measures unattractive from an economic standpoint and often not cost-effective.<\/p>\n<p>In some cases, local authorities set a minimum exhaust gas temperature at the outlet of the chimney to ensure adequate dispersion of the exhaust gases and the absence of a visible smoke plume. Additionally, some companies may voluntarily adopt such practices to improve their image since the general public often interprets the presence of a visible smoke plume as a sign of environmental pollution, while the absence of a smoke plume can be seen as a sign of clean production.<\/p>\n<p>All of this leads to situations where enterprises may deliberately heat flue gases before releasing them into the atmosphere under certain weather conditions. However, understanding the composition of the gases discharged from a boiler operating on natural gas (which has been detailed above) makes it clear that the white \"smoke\" coming from the stack (when correctly adjusting the burning mode) is mostly water vapor generated as a result of the combustion of natural gas in the boiler's combustion chamber.<\/p>\n<p>Combating corrosion requires the use of materials that are resistant to its negative effects (such materials exist and can be applied in installations that use gas, petroleum products, and even waste as fuel), as well as organizing the collection, processing of acidic condensate, and its disposal.<\/p>\n<p><img decoding=\"async\" alt=\"Utilization of Flue Gas Heat: Ecology for Profit\" src=\"\/wp-content\/uploads\/2019\/07\/2fd11a8e0fb31fa32efb575038855137.jpg\" style=\"display:block;margin: 0 auto;\" \/><\/p>\n<h2>Technology<\/h2>\n<p>\nImplementing a range of measures to reduce the temperature of flue gases after the boiler at an existing enterprise ensures increased efficiency of the entire system, which includes the boiler unit, primarily utilizing the boiler itself (the heat generated within it).<\/p>\n<p>The concept of such solutions, in essence, boils down to one idea: a heat exchanger is installed in the flue gas duct before the chimney, which absorbs the heat from the flue gases using a cooling medium (for instance, water). This water can serve as the final heat carrier that needs to be heated, or it can act as an intermediate agent that transfers heat through additional heat exchange equipment to another circuit.<\/p>\n<p>The fundamental scheme is presented in the figure:<\/p>\n<p><img decoding=\"async\" alt=\"Utilization of Flue Gas Heat: Ecology for Profit\" src=\"\/wp-content\/uploads\/2019\/07\/8d8adf7d5b3b1d113a6d4ba35f773620.jpg\" style=\"display:block;margin: 0 auto;\" \/><br \/>\nThe collection of the resulting condensate occurs directly within the volume of the new heat exchange device, which is made from corrosion-resistant materials. This is because the temperature threshold of the dew point for the moisture contained in the discharged gases is exceeded precisely within the heat exchanger. Thus, not only the physical heat from the flue gases is effectively utilized, but also the latent heat of condensation of the water vapor contained in them. The device itself must be designed in such a way that its construction does not create excessive aerodynamic resistance, thereby avoiding adverse operational conditions for the boiler unit.<\/p>\n<p>The design of the heat exchanger can either be a conventional regenerative heat exchanger, where heat transfer from gases to liquids occurs through a separating wall, or a contact heat exchanger, where flue gases come into direct contact with water that is sprayed by nozzles into their flow.<\/p>\n<p>For the regenerative heat exchanger, addressing the acidic condensate issue boils down to organizing its collection and neutralization. In the case of the contact heat exchanger, a slightly different approach is used, somewhat akin to periodically venting the circulating water supply system: as the acidity of the circulating fluid increases, a certain quantity is drawn off into a storage tank, where it is treated with reagents followed by disposal of the water into the drainage system or directed into the technological cycle.<\/p>\n<p>Certain applications of flue gas energy may be limited due to the temperature difference between the gases and the specific temperature requirements of the energy-consuming process. However, even for such seemingly dead-end situations, an approach has been developed that relies on qualitatively new technologies and equipment.<\/p>\n<p>To enhance the efficiency of the flue gas heat recovery process, innovative solutions based on heat pumps are increasingly being used as key elements of the system in global practice. In certain sectors of industry (for instance, bioenergy), such solutions are employed in most of the boilers being put into operation. Additional savings in primary energy resources are achieved by using more reliable and technologically advanced absorption lithium-bromide heat pumps (ABHPs), which require heat to operate rather than electricity (this can often be unused waste heat, which is abundantly available at nearly any enterprise). This heat from an external heating source activates the internal cycle of the ABHP, allowing it to convert the available temperature potential of the exhaust gases and transfer it to hotter media.<\/p>\n<p><img decoding=\"async\" alt=\"Utilization of Flue Gas Heat: Ecology for Profit\" src=\"\/wp-content\/uploads\/2019\/07\/82daf6ec9c80cb633f21101c4471a195.jpg\" style=\"display:block;margin: 0 auto;\" \/><\/p>\n<h2>Result<\/h2>\n<p>\nThe cooling of flue gases from the boiler using such solutions can be quite significant \u2013 down to 30 and even 20 \u00b0C from the initial 120-130 \u00b0C. The heat obtained is sufficient to heat water for chemical water treatment needs, supply, hot water supply, and even district heating.<\/p>\n<p>Fuel savings can reach 5-10%, while the efficiency of the boiler unit can increase by 2-3%.<\/p>\n<p>Thus, the implementation of this technology allows for the resolution of several tasks simultaneously. These include:<\/p>\n<ul>\n<li>maximizing the complete and useful utilization of heat from flue gases (as well as the latent heat of condensation of water vapors),<\/li>\n<li>reducing the volume of NOx and SOx emissions into the atmosphere,<\/li>\n<li>gaining an additional resource \u2013 purified water (which can find useful application in any enterprise, for example, as make-up water for district heating and other water circuits),<\/li>\n<li>elimination of the smoke plume (which becomes barely noticeable or disappears entirely).<\/li>\n<\/ul>\n<p>\nPractice shows that the feasibility of using such solutions primarily depends on:<\/p>\n<ul>\n<li>the possibility of useful utilization of the existing heat in the flue gases,<\/li>\n<li>the duration of the use of the obtained thermal energy throughout the year,<\/li>\n<li>the cost of energy resources at the enterprise,<\/li>\n<li>the presence of excess permissible concentration of emissions for NOx and SOx (as well as the strictness of local environmental legislation),<\/li>\n<li>the method of neutralizing condensate and options for its further use.<\/li>\n<\/ul>\n<p>Source: <a content=\"nofollow\" rel=\"nofollow\" href=\"https:\/\/habr.com\/ru\/company\/lanit\/blog\/460419\/\">habr.com<\/a><\/p>","protected":false,"gt_translate_keys":[{"key":"rendered","format":"html"}]},"excerpt":{"rendered":"<p>\u0412 \u043f\u043e\u0438\u0441\u043a\u0430\u0445 \u0441\u043f\u043e\u0441\u043e\u0431\u043e\u0432 \u043f\u043e\u0432\u044b\u0448\u0435\u043d\u0438\u044f \u044d\u0444\u0444\u0435\u043a\u0442\u0438\u0432\u043d\u043e\u0441\u0442\u0438 \u043f\u0440\u0435\u0434\u043f\u0440\u0438\u044f\u0442\u0438\u0439 \u044d\u043d\u0435\u0440\u0433\u0435\u0442\u0438\u0447\u0435\u0441\u043a\u043e\u0433\u043e \u0441\u0435\u043a\u0442\u043e\u0440\u0430, \u0430 \u0442\u0430\u043a\u0436\u0435 \u0434\u0440\u0443\u0433\u0438\u0445 \u043f\u0440\u043e\u043c\u044b\u0448\u043b\u0435\u043d\u043d\u044b\u0445 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[&hellip;]<\/p>\n","protected":false,"gt_translate_keys":[{"key":"rendered","format":"html"}]},"author":1,"featured_media":27435,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[702],"tags":[],"class_list":["post-36635","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news"],"aioseo_notices":[],"aioseo_head":"\n\t\t<!-- All in One SEO 5.0.1.1 - aioseo.com -->\n\t<meta name=\"description\" content=\"\u0412 \u043f\u043e\u0438\u0441\u043a\u0430\u0445 \u0441\u043f\u043e\u0441\u043e\u0431\u043e\u0432 \u043f\u043e\u0432\u044b\u0448\u0435\u043d\u0438\u044f \u044d\u0444\u0444\u0435\u043a\u0442\u0438\u0432\u043d\u043e\u0441\u0442\u0438 \u043f\u0440\u0435\u0434\u043f\u0440\u0438\u044f\u0442\u0438\u0439 \u044d\u043d\u0435\u0440\u0433\u0435\u0442\u0438\u0447\u0435\u0441\u043a\u043e\u0433\u043e \u0441\u0435\u043a\u0442\u043e\u0440\u0430, \u0430 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