1. Pharos University جامعه فاروس Faculty of Engineering كلية الهندسة Petrochemical Department قسم البتروكيماويات PE 330 ENERGY CONSERVATION LECTURE (9) ENERGY RECOVERY SYSTEMS: 1- Introduction: Process streams at high pressure or temperature, and those containing combustible material, contain energy that can be usefully recovered. Whether it is economic to recover the energy content of a particular stream will depend on the value of the energy that can be usefully extracted and the cost of recovery.

2.  The value of the energy will depend on the primary cost of energy at the site. It may be worth while recovering energy from a process stream at a site where energy costs are high but not where the primary energy costs are low.  The cost of recovery will be the capital and operating cost of any additional equipment required.  In all processes the efficient utilisation of energy recovery techniques will reduce product c ost.

3. 2-ENERGY RECOVERY SYSTEMS: 2-1 Heat exchange: The most common energy-recovery technique is to utilise the heat in a high-temperature process stream to heat a colder stream: saving steam costs; and also cooling water, if the hot stream requires cooling. Conventional shell and tube exchangers are normally used. More total heat-transfer area will be needed, over that for steam heating and water cooling, as the overall driving forces will be smaller. The cost of recovery will be reduced if the streams are located conveniently close. The amount of energy that can be recovered will depend on the temperature, flow, heat capacity, and temperature change possible, in each stream.

4. A reasonable temperature driving force must be maintained to keep the exchanger area to a practical size. The most efficient exchanger will be the one in which the shell and tube flows are truly countercurrent. Multiple tube pass exchangers are usually used for practical reasons. With multiple tube passes the flow will be part counter-current and part co-current and temperature crosses can occur, which will reduce the efficiency of heat recovery

5. 2-2 Waste-heat boilers: If the process streams are at a sufficiently high temperature the heat recovered can be used to generate steam. Waste-heat boilers are often used to recover heat from furnace flue gases and the process gas streams from high-temperature reactors. The pressure, and superheat temperature, of the stream generated will depend on the temperature of the hot stream and the approach temperature permissible at the boiler exit.As with any heat-transfer equipment, the area required will increase as the mean temperature driving force (log Mean ∆T) is reduced. Both fire tube and water tube boilers are used.

6. 2-3 Low-grade fuels: The waste products from any process (gases, liquids and solids) which contain significant quantities of combustible material can be used as low-grade fuels; for raising steam or direct process heating. Their use will only be economic if the intrinsic value of the fuel justifies the cost of special burners and other equipment needed to burn the waste. If the combustible content of the waste is too low to support combustion, the waste will have to be supplemented with higher calorific value primary fuels.

7. 2-3-1 Reactor off-gases : The off-gases (vent gas) from reactors, and recycle stream purges are often of high enough calorific value to be used as fuels. The calorific value of a gas can be calculated from the heats of combustion of its constituents; Other factors which, together with the calorific value, will determine the economic value of an off-gas as a fuel are the quantity available and the continuity of supply. Waste gases are best used for steam raising, rather than for direct process heating, as this decouples the source from the use and gives greater flexibility.

8. 2-3-2 Liquid and solid wastes: Combustible liquid and solid waste can be disposed of by burning, which is usually preferred to dumping. Incorporating a steam boiler in the incinerator design will enable an otherwise unproductive, but necessary operation, to save energy. 2-4:High-pressure process streams: Where high-pressure gas or liquid process streams are throttled to lower pressures, energy can be recovered by carrying out the expansion in a suitable turbine.

9. : 2-4-1Gas streams The economic operation of processes which involve the compression and expansion of large quantities of gases, such as ammonia synthesis, nitric acid production and ai r separation, depends on the efficient recovery of the energy of compression. The energy recovered by expansion is often used to drive the compressors directly. If the gas contains condensible components it may be advisable to consider heating the gas by heat exchange with a higher temperature process stream before expansion. The gas can then be expanded to a lower pressure without condensation and the power generated increased.

10. Example:

11. Solution:

13. Equations used: