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media. Because this extra energy in the exhausted flue gas cannot be transferred directly into the working media inside the equipment, instead of being exhausted into the atmosphere at high temperatures, the heat energy should be recovered by a method similar to the one described later in Chapter 5. As a general rule of thumb, for every 40°F reduction in exiting stack gas temperature, the overall efficiency of the process is increased by 1% [26]. Other sources of this inefficiency could be a faulty part in the equipment or fouling on the heat transfer surface. While it is still a good idea to recover the heat in the exhaust stack, this will not make up for the problems associated with the equipment and the source of the problem should be corrected to greatly increase the efficiency and productivity of the process. Excess Air in the Combustion Process During a combustion process, the maximum temperature possible occurs when there is just enough air to mix with the fuel and complete combustion is able to occur. This is called stoichiometric combustion and is not realistic for an actual combustion processes due to mixing limitations between the gasses. Although stoichiometric combustion is not realistic, it is desirable to only supply the minimum amount of excess air to the process to allow for complete combustion to occur. Complete combustion is desired so that unburned fuel particles are not sent through the stack. Incomplete combustion is not only a waste of the purchased fuel but also has the potential to create a safety hazard by creating the possibility for combustion to occur in undesired locations of the process. The reasoning behind using only the minimum amount of excess air is that for every molecule of O2 found in air, assuming air is the source of oxygen for the process, there are 3.76 molecules of nitrogen that come along with it. This nitrogen is, for by far the most part, inert to the combustion process, however it absorbs energy by being heated from the initial temperature before combustion to the final temperature after combustion. This 12PDF Image | TUDY OF LOW-GRADE WASTE HEAT RECOVERY
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