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Once the system has been properly designed, the economic side of the project must be determined. To estimate the implementation cost of the entire system, cost estimating handbooks as well as online retailers and supplier quotes can be used to find the approximate purchasing and labor cost for each component. The amount of money that is saved from implementing the system can then be found by determining what source and the amount of energy which is being offset, in this case natural gas or electricity. From this information and an average energy cost for each of the sources, an estimated monetary savings can be found. This information together can be used to determine a simple payback of the system in years. System Description For this analysis, an actual industrial facility was chosen to simulate a realistic heat recovery situation. This facility contains two 400 hp natural gas fired boilers with one in operation continuously and one in standby as a backup. For the analysis, the system is assumed to operate with one boiler in fully loaded operation for all 8,760 hours a year. The boilers are used to create 120 psig steam air for manufacturing high precision lost foam casting molds. The exhaust gas conditions were measured and found to average 485°F with a flow rate of 4,050 cfm. This airflow rate was found from a simple combustion chemistry analysis of the system based on a measured O2 exhaust gas content of 2.2% and the described exhaust temperature. Under these conditions the boilers are estimated to consume around 55,000 MMBtu a year in natural gas. The facility layout can be seen in the following drawing. The facility consists of a bead storage room which is maintained at a temperature of 70°F year round and, because of noxious gas being present, air is circulated regularly. 86PDF Image | TUDY OF LOW-GRADE WASTE HEAT RECOVERY
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