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D APPENDIX D: TECHNOLOGY SOLUTIONS FOR ENERGY RECOVERY Direct Heating District heating systems use a central plant in an urban area to supply heat to multiple buildings and complexes. Several plants operated by Ford Motor Company are supplied by district heating. For example, Ford-Werke AG headquarters (DE) uses district heat and saves 73,500 tons of coal and 3,500 tons of fuel oil, while reducing CO2 emissions by 60% annually. Alternative Fuels Some industrial metal processes produce waste products that can be incinerated exothermically to provide an ideal fuel for the boiler. The energy saved by using some of these waste streams (particularly chemical waste streams) must be balanced with the potential release of environmental toxins into the atmosphere. At the Orion Assembly Plant (MI) in 1998, in affiliation with the U.S. EPA Landfill Methane Outreach Program, General Motors replaced the coal burned in their boilers with landfill gas from a nearby landfill, reducing coal use by 60,000 tons on an annual basis (roughly equivalent to 1.5 TBtu, or 30% of the fuel used for heating the plant). In addition, the new plant reduced sulfur dioxide emissions by 40% and nitrogen by 46%. The EPA estimates that more than 700 landfills across the U.S. could install economically viable energy recovery systems; however, plants must be located near viable landfills to implement the measure. Boiler – Recover Heat from Flue Gas The motor vehicle industry in the U.S. spends about $3.6 B on energy annually. Over 70 assembly plants currently produce ~13 million cars and trucks each year. According to the vehicle manufacturing industry, heat recovery from the flue gas is the best opportunity for heat recovery in the boiler house. Heat from flue gasses can be used to preheat boiler feed water in an economizer. While this measure is fairly common in large boilers, there is often room for more heat recovery. The limiting factor for flue gas heat recovery is that the economizer wall temperature must not drop below the dew point of acids in the flue gas. Traditionally, this has been done by keeping the flue gases exiting the economizer at a temperature significantly above the acid dew point. In fact, the economizer wall temperature is much more dependent on the feed water temperature than the flue gas temperature because of the high heat transfer coefficient of water. As a result, it makes more sense to preheat the feed water to close to the acid dew point before it enters the economizer. This allows the economizer to be designed so that the flue gas exiting the economizer is just barely above the acid dew point. 1% of fuel use is saved for every 45oF reduction in exhaust gas temperature. Since exhaust gas temperatures are already quite low, but can still take advantage of using the higher temperature feed water mentioned above, an estimated 1% savings is possible. 1. “Energy Efficiency Improvement and Cost Saving Opportunities for the Vehicle Assembly Industry,” Galitsky, C. and Worrell, E., LLNL, 2001. 121PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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