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Recovery
from Genset gases
The
Client : A large beverage manufacturer near Palakkad, Kerala.
The
opportunity : The customer was running a 750KW genset for 4,000 hours per
annum. They were also using low pressure steam at 3 bar for beverage
preparation.
The
solution : The corrosively of sulphur in diesel fumes and soot content is
the main hurdle. Guha Industries planned a once-through steam
boiler, discharging at 3 bar, around a welded "H" type
finned tube exchanger. The flue gas side surface was coated with
molten aluminium to prevent corrosion. The hold up of steam in the
exchanger bundle was deliberately planned to be less than 22 liters to
avoid the purview of the Indian Boiler Regulations.
The
savings : At 60% load operation, reducing the stack from 400oC
to 200oC generates more than 300 kg/h steam. For 4,000
hours operation, this translates into savings of INRs 840,000/- (US$
18,000/-). Payback is around 9 months. Saving potential would
be more at higher loads.
Recovery
of waste heat from kiln gases
The
Client : A leading Chemicals factory in Tamil Nadu
The
opportunity : The customer was venting about 7,500 kg/h of kiln gases at
350 to 400oC. There is a high heat requirement for drying
and evaporation.
The
solution : High particulate matter in the kiln vent was the main hurdle to
recovery. A multiclone was put before the recuperator to knock down
the particulates content. A plain tube, multipass bundle with
thermic fluid in the tube side was used to recover heat from the flue
gas. The thermic fluid enters the bundle at 150oC, and
leaves at 200oC, knocking down the kiln gas to 170oC.
Thermic fluid was used to replace part of the heat supplied by the
existing steam boiler.
The
savings : About INRs 960,000/- (US$ 21,000) per annum direct energy
savings, and pay-back within a year. Direct use of bag house after
the recovery system; as against using a dilution air fan to reduce the
temperature, followed by larger bag house.
