Evaluation of retrofitting a conventional natural gas fired boiler into a condensing boiler

The exit flue gas temperature of a conventional gas fired boiler is usually high and a great amount of heat energy is lost to the environment. If both sensible heat and latent heat can be recovered by adding a condensing heat exchanger, the efficiency of the boiler can be increased by as much as 10%. In this paper, based on combustion and heat transfer calculations, the recoverable heat and the efficiency improvement potential of different heat recovery schemes at various exit flue gas temperatures are presented by performing design calculations. The payback period method has been used to analyze the feasibility of retrofitting a conventional gas fired boiler into a condensing boiler in a heating system in detail. The results show that the most economical exit flue gas temperature is 40–55 °C when a conventional natural gas fired boiler is retrofitted into a condensing boiler simply by adding a condensing heat exchanger. It is feasible to use the return water of a heating system as the cooling medium of the condensing heat exchanger because the return temperature varies with the ambient temperature and is lower than the dew point of the water vapor in the flue gas in most periods of a heating season in some regions, which has been verified by retrofitted case.     

天然气锅炉改造为冷凝式锅炉的经济性评价

燃气供热锅炉排烟温度较高，带走了大量的热能。如果加装冷凝式换热器回收烟气的显热及潜热，可以大大提高锅炉效率，但是加装换热器必然增加设备成本。本文通过对冷凝式换热器设计计算，计算出不同排烟温度下的热能回收设备投资回收期，从经济上分析了天然气锅炉改造为冷凝式锅炉的可行性，并给出了锅炉最佳排烟温度。     

Techno-economic analysis of a novel hybrid heat pump system to recover waste heat and condensate from the low-temperature boiler exhaust gas

This paper is based on the proposal of a new waste heat recovery (WHR) system, which can be utilized to heat the boiler return water, boiler supply air, and building heating air. The system is the combination of an indirect contact condensing unit (IDCCU), a mechanical compression heat pump, and two air preheaters. The system is modeled on the basis of mass and energy balance and then thermodynamically analyzed. Improved performance results were obtained in the form of an increase in the boiler's energy efficiency of about 10.47%, with 4.87% increase in exergy efficiency. The coefficient of performance (COP) of the heat pump was increased from 1.23 to 1.45 by the addition of an air heater in the conventional heat pump. The exergy destruction in each component is calculated. Sensitivity analysis was performed to check the influence of different operating parameters on the performance of the WHR system and boiler. It can be observed from the results that for a specific refrigerant temperature and a calculated amount of mass, flow rate can maximize the condensation efficiency of IDCCU by decreasing the flue gas temperature, while the use of the air heater can further reduce the flue gas temperature, and a stream of hot air can be utilized for space heating. A comparison is made with the other system on a performance basis. The results shows a clear difference in efficiencies and profit earned.     

船舶垃圾焚烧炉及柴油动力装置余热综合利用系统

从船舶节能角度出发,提出了一种综合利用船舶垃圾焚烧炉及柴油动力装置余热的回收系统。对系统各部件和工质参数进行计算,为设备设计和选型提供依据;对系统进行?平衡和热平衡计算,系统中锅炉的?损失最大为68.1%,冷凝器的?损失最小为3.17%;对系统进行经济性分析,结果表明系统能量利用率εE提高了3.54%,动力装置有效热效率ηe提高了3.11%,系统获得额外约1300（万元/年）的收益,投资回收期约为1.6年,对该余热回收系统进行投资是切实可行的。     

Energy and exergy analyses of space heating in buildings

In the present study, energy and exergy analyses are presented for the whole process of space heating in buildings. This study is based on a pre-design analysis tool, which has been produced during ongoing work for the International Energy Agency (IEA) formed within the Energy Conservation in Buildings and Community Systems Programme (ECBCSP) Annex 37. Throughout this paper, in all of the calculations such as heat losses and gains were taken according to Turkish Standards Institution TSE, which is in accordance with the European Standard TS EN ISO 13789. In the analysis, heating load is taken account but cooling load is neglected and the calculations presented here are done using steady state conditions. The analysis is applied to an office in Izmir with a volume of 720 m³ and a net floor area of 240 m² as an example of application. Indoor and exterior air temperatures are 20 °C and 0 °C, respectively. It is assumed that the office is heated by a liquid natural gas (LNG) fired conventional boiler, an LNG condensing boiler and an external air–air heat pump. With this study, energy and exergy flows are investigated. Energy and exergy losses in the whole system are quantified and illustrated. The highest efficiency values in terms of energy and exergy were found to be 80.9% for external air–air heat pump and 8.69% for LNG condensing boiler, respectively.     

Exergy analysis of hydrogen production plants based on biomass gasification

Biomass gasification is a promising option for the sustainable production of hydrogen rich gas. Five different commercial or pilot scale gasification systems are considered for the design of a hydrogen production plant that generates almost pure hydrogen. For each of the gasification technique models of two different hydrogen production plants are developed in Cycle-Tempo: one plant with low temperature gas cleaning (LTGC) and the other with high temperature gas cleaning (HTGC). The thermal input of all plants is 10 MW of biomass with the same dry composition. An exergy analysis of all processes has been made. The processes are compared on their thermodynamic performance (hydrogen yield and exergy efficiency). Since the heat recovery is not incorporated in the models, two efficiencies are calculated. The first one is calculated for the case that all residual heat can be applied, the case with ideal heat recovery, and the other is calculated for the case without heat recovery. It is expected that in real systems only a part of the residual heat can be used. Therefore, the actual value will be in between these calculated values. It was found that three processes have almost the same performance: The Battelle gasification process with LTGC, the FICFB gasification process with LTGC, and the Blaue Turm gasification process with HTGC. All systems include further processing of the cleaned gas from biomass gasification into almost pure hydrogen. The calculated exergy efficiencies are, respectively, 50.69%, 45.95%, and 50.52% for the systems without heat recovery. The exergy efficiencies of the systems with heat recovery are, respectively, 62.79%, 64.41%, and 66.31%. The calculated hydrogen yields of the three processes do not differ very much. The hydrogen yield of the Battelle LTGC process appeared to be 0.097 kg (kg_{(dry biomass)})⁻¹, for the FICFB LTGC process a yield of 0.096 kg (kg_{(dry biomass)})⁻¹ was found, and for the Blaue Turm HTGC 0.106 kg (kg_{(dry biomass)})⁻¹.     

Energy savings in the combustion based process heating in industrial sector

Energy efficiency and savings strategies in the combustion based industrial process heating has been reviewed comprehensively and presented in this paper. This work compiles latest literatures in terms of thesis, journal articles, conference proceedings, web materials, reports, books, handbooks on industrial process heating systems in the industrial sector. Different types of equipment used (i.e., recuperator, regenerators, heat wheels, heat pipes, economizers, etc.) and energy savings are reviewed in various industrial processes heating. Based on the review results, it is found that significant amounts of energy could be saved by using heat recovery system in the industrial process heating. By using recuperator up to 25% energy can be saved in the furnace. In the case of boiler, by using economizers 10% to 20% energy can be saved. Economic analysis shows that the payback period of recuperator and economizer are normally less than 2 years. It is also found that the payback period is lower when operating hour is comparatively high.     

A comparative investigation of various greenhouse heating options using exergy analysis method

This study deals with modeling and analyzing the performance of greenhouses from the power plant through the heating system to the greenhouse envelope using exergy analysis method, the so-called low exergy or LowEx approach, which has been and still being successfully used in sustainable buildings design, for the first time to the best of the author’s knowledge. For the heating applications, three options are studied with (i) a solar assisted vertical ground-source heat pump greenhouse heating system, (ii) a wood biomass boiler, and (iii) a natural gas boiler, which are driven by renewable and non-renewable energy sources. In this regard, two various greenhouses, the so-called small greenhouse and large greenhouse, considered have heat load rates of 4.15 kW and 7.5 MW with net floor areas of 11.5 m² and 7.5 ha, respectively. The overall exergy efficiency values for Cases 1–3 (solar assisted vertical ground-source heat pump, natural gas boiler and wood biomass boiler) of the small greenhouse system decrease from 3.33% to 0.83%, 11.5% to 2.90% and 3.15% to 0.79% at varying reference state temperatures of 0 to 15 °C while those for Cases 1 and 2 (wood biomass and natural gas boilers) of the large greenhouse system decrease from 2.74% to 0.11% and 4.75% to 0.18% at varying reference state temperatures of −10% to 15 °C. The energetic renewability ratio values for Cases 1 and 3 of the small greenhouse as well as Case 1 of the large greenhouse are obtained to be 0.28, 0.69 and 0.39, while the corresponding exergetic renewability ratio values are found to be 0.02, 0.64 and 0.29, respectively.     

An application of energy and exergy analysis in residential sector of Malaysia

In this paper, the useful concept of energy and exergy utilization is defined, analyzed and applied to the residential sector of Malaysia by taking into account the energy and exergy flows for a period of 8 years from the year 1997 to 2004. The energy and exergy efficiencies are determined for the devices used in this sector and found to be 70% and 28%, respectively. Energy and exergy flow diagrams for the overall efficiencies of Malaysian residential sector are also illustrated in this paper. It is found that the current methodology applied in Saudi Arabia is suitable to analyze energy and exergy use in Malaysian residential sector. It has been found that the exergy efficiency of the Malaysian residential sector appears to be much lower than its corresponding energy efficiency. It has been observed that about 21% of total exergy losses are caused by refrigerator-freezer and 12% of total loss is caused by air conditioner. Washing machine, fan and rice cooker contribute about 11%, 10% and 8% of total exergy losses, respectively.     

Dynamic multi-objective optimization applied to a solar-geothermal multi-generation system for hydrogen production,desalination, and energy storage

The design of optimal energy systems is vital to achieving global environmental and economic targets. In the design of solar-geothermal multi-generation systems, most previous investigations have relied on the static multi-objective optimization approach (SMOA), which may leave considerable room for improvement under certain conditions. In this numerical study, the optimal condition at which to operate a solar-geothermal multi-generation system – which can simultaneously produce hydrogen, fresh water, electricity, and heat, along with storing energy ? is determined via a dynamic multi-objective optimization approach (DMOA). Optimization is performed using a combination of NSGA-II and TOPSIS, and the results are benchmarked against those of SMOA. The decision variables include the solar area, geothermal water extraction mass flow, and hydrogen storage pressure. The objective functions include the production of electricity, heat, hydrogen, and fresh water, along with the exergy and energy efficiencies and the payback period. It is found that when compared with SMOA, DMOA can significantly improve all the objective functions. The annual production of electricity, heat, hydrogen, and fresh water increases by 14.4, 16.1, 13.5, and 14.3%, respectively, while the average annual exergy and energy efficiencies increase by 5.2 and 3.0%, respectively. The use of DMOA also reduces the payback period from 5.56 to 4.43 years, with a 4.4% reduction in hydrogen storage pressure. This shows that compared with a static approach such as SMOA, DMOA can improve the exergy and energy efficiencies, economic viability, and safety of a solar-geothermal multi-generation system.     

Proposal and analysis of a novel ammonia–water cycle for power and refrigeration cogeneration

Cogeneration has improved sustainability as it can improve the energy utilization efficiency significantly. In this paper, a novel ammonia-water cycle is proposed for the cogeneration of power and refrigeration. In order to meet the different concentration requirements in the cycle heat addition process and the condensation process, a splitting /absorption unit is introduced and integrated with an ammonia–water Rankine cycle and an ammonia refrigeration cycle. This system can be driven by industrial waste heat or a gas turbine flue gas. The cycle performance was evaluated by the exergy efficiency, which is 58% for the base case system (with the turbine inlet parameters of 450 °C/11.1 MPa and the refrigeration temperature below −15 °C). It is found that there are certain split fractions which maximize the exergy efficiency for given basic working fluid concentration. Compared with the conventional separate generation system of power and refrigeration, the cogeneration system has an 18.2% reduction in energy consumption.     

Spark spread – A screening parameter for combined heating and power systems

Combined heating and power (CHP) systems may be considered for installation if they produce savings over conventional systems with separate heating and power. For a CHP system with a natural gas engine as the prime mover, the difference between the price of natural gas and the price of purchased electricity, called spark spread, is an indicator as to whether a CHP system might be considered or not. The objective of this paper is to develop a detailed model, based on the spark spread, that compares the electrical energy and heat energy produced by a CHP system against the same amounts of energy produced by a traditional, or separate heating and power (SHP) system that purchases electricity from the grid. An expression for the spark spread based on the cost of the fuel and some of the CHP system efficiencies is presented in this paper as well as an expression for the payback period for a given capital cost and spark spread. The developed expressions allow determining the required spark spread for a CHP system to produce a net operational savings over the SHP in terms of the performance of system components. Results indicate that the spark spread which might indicate favorable payback varies based on the efficiencies of the CHP system components and the desired payback period. In addition, a new expression for calculating the payback period for a CHP system based on the CHP system capital cost per unit of power output and fuel cost is proposed.     

Consteel电炉余热锅炉的热平衡计算方法研究

针对Consteel电炉余热锅炉烟气入口参数不稳定的特点,得到了余热锅炉的各项热损失、锅炉效率、有效利用热量和蒸发量的计算公式。对65t Consteel电炉炼钢设备余热锅炉进行了热平衡计算,计算表明,锅炉的排烟热损失随烟气入口温度的降低而增加,而锅炉效率、有效利用热量和蒸发量随烟气入口温度的降低而降低,锅炉的平均蒸发量为23．1t／h。     

Efficiency assessment of an integrated gasifier/boiler system for hydrogen production with different biomass types

In this study, we utilize some experimental data taken from the literature, especially on the air-blown gasification characteristics of six different biomass fuels, namely almond shell (ASF), walnut pruning (WPF), rice straw (RSF), whole tree wood chips (WWF), sludge (SLF) and non-recyclable waste paper (NPF) in order to study the thermodynamic performance of an integrated gasifier–boiler power system for its hydrogen production. In this regard, both energy and exergy efficiencies of the system are investigated. The exergy contents of different biomass fuels are calculated to be ranging from 15.89 to 22.07 MJ/kg, respectively. The hydrogen concentrations based on the stack gases at the cyclone exit are determined to be between 7 and 18 (%v/v) for NPF and ASF. Also, percentages of combustible vary from 30% to 46%. The stack gas has physical and chemical exergies. The total specific exergy rates are calculated and illustrated. These values change from 3.54 to 6.41 MJ/kg. Then, two types of exergy efficiencies are calculated, such as that exergy efficiency 1 is examined via all system powers, exergy and efficiency 2 is calculated according to specific exergy rates of biomass fuels and product gases. While the exergy efficiencies 1 change between 4.33% and 11.89%, exergy efficiencies 2 vary from 18.33% to 39.64%. Also, irreversibilities range from 9.76 to 18.02 MJ/kg. Finally, we investigate how nitrogen contents of biomass fuels affect on energy and exergy efficiencies. The SLF has the highest amount of nitrogen content as 5.64% db while the NPF has the lowest one as 0.14% db. The minimum and maximum exergetic efficiencies belong to the same fuels. Obviously, the higher the nitrogen content the lower the efficiency based on an inverse ratio between exergy efficiency and nitrogen content.     

特殊结构直流锅炉回收退火炉烟气佘热的实际应用

介绍了退火炉余热资源回收利用的现状,结合传统的退火炉烟气余热回收方法,提出了一种利用直流锅炉产生蒸汽回收烟气余热的新方法.项目改造后每年可为企业节省运行费用84万元,投资回收期为36天,为退火炉进行节能降耗改造提供了一种新方法以供参考和借鉴.     

Performance analysis of an industrial waste heat‐based trigeneration system

The thermodynamic performance of an industrial waste heat recovery‐based trigeneration system is studied through energy and exergy efficiency parameters. The effects of exhaust gas inlet temperature, process heat pressure, and ambient temperature on both energy and exergy efficiencies, and electrical to thermal energy ratio of the system are investigated. The energy efficiency increases while electrical to thermal energy ratio and exergy efficiency decrease with increasing exhaust gas inlet temperature. On the other hand, with the increase in process heat pressure, energy efficiency decreases but exergy efficiency and electrical to thermal energy ratio increase. The effect of ambient temperature is also observed due to the fact that with an increase in ambient temperature, energy and exergy efficiencies, and electrical to thermal energy ratio decrease slightly. These results clearly show that performance evaluation of trigeneration system based on energy analysis is not adequate and hence more meaningful evaluation must include exergy analysis. The present analysis contributes to further information on the role of exhaust gas inlet temperature, process heat pressure, ambient temperature influence on the performance of waste heat recovery‐based trigeneration from a thermodynamic point of view. Copyright © 2009 John Wiley & Sons, Ltd.     

有机热载体炉烟气余热回收技术浅析

长期以来,有机热载体炉排烟温度偏高,造成大量的能源浪费,严重影响了锅炉运行的经济性。为减少热能损失,对烟气余热回收技术的可行性方案、工程应用实例进行了阐述;并指出通过锅炉烟气余热利用技术回收排烟中的显热和潜热,可以大大提高有机热载体炉的热效率,实现节能降耗。     

Possibilities for gas turbine and waste incinerator integration

The aggressive nature of the flue gases in municipal waste incinerators does not allow the temperature of steam in the boiler to rise above 400°C. An increase in steam temperature can be achieved by external superheating in a heat recovery steam generator positioned behind a gas turbine, so that steam of a higher energy content becomes available for electricity production. The paper addresses two basic schemes. In one case, steam generated at a waste-to-energy plant is superheated in a combined-cycle plant that operates in parallel. In the other case, the exhaust from a gas turbine plant is sent through a superheater section to the waste incinerator's boiler providing preheated combustion air. Performance of these configurations together with two modified schemes was analyzed in terms of efficiency, natural gas consumption and boiler surface area. An exergy analysis of the cases was carried out. The results showed that the integrated options can effect a substantial increase in efficiency. The hot windbox configuration was found the most effective solution, offering a smaller boiler surface area along with a moderate rate of natural gas consumption.     

Effect of wall orientation on the optimum insulation thickness by using a dynamic method

A comprehensive economic analysis has been performed to inter-relate the optimum thickness of insulation materials for various wall orientations. The yearly cooling and heating transmission loads of building walls were determined by use of implicit finite-difference method with regarding steady periodic conditions under the climatic conditions of Elaz??, Turkey. The economic model including the cost of insulation material and the present value of energy consumption cost over lifetime of 10 years of the building was used to find out the optimum insulation thickness, energy savings and payback periods for all wall orientations. Considered insulation materials in the analysis were extruded polystyrene and polyurethane. As a result, the optimum insulation thickness of extruded polystyrene was found to be 5.5 cm for south oriented wall and 6 cm for north, east and west oriented walls. Additionally, the lowest value of the optimum insulation thickness and energy savings were obtained for the south oriented wall while payback period was almost same for all orientations.     

Condensing boiler applications in the process industry

Major challenging issues such as climate change, energy prices and fuel security have focussed the attention of process industries on their energy efficiency and opportunities for improvement. The main objective of this research study was to investigate technologies needed to exploit the large amount of low grade heat available from a flue gas condensing system through industrial condensing boilers. The technology and application of industrial condensing boilers in various heating systems were extensively reviewed. As the condensers require site-specific engineering design, a case study was carried out to investigate the feasibility (technically and economically) of applying condensing boilers in a large scale district heating system (40 MW). The study showed that by recovering the latent heat of water vapour in the flue gas through condensing boilers, the whole heating system could achieve significantly higher efficiency levels than conventional boilers. In addition to waste heat recovery, condensing boilers can also be optimised for emission abatement, especially for particle removal. Two technical barriers for the condensing boiler application are corrosion and return water temperatures. Highly corrosion-resistant material is required for condensing boiler manufacture. The thermal design of a “case study” single pass shell-and-tube condensing heat exchanger/condenser showed that a considerable amount of thermal resistance was on the shell-side. Based on the case study calculations, approximately 4900 m² of total heat transfer area was required, if stainless steel was used as a construction material. If the heat transfer area was made of carbon steel, then polypropylene could be used as the corrosion-resistant coating material outside the tubes. The addition of polypropylene coating increased the tube wall thermal resistance, hence the required heat transfer area was approximately 5800 m². Net Present Value (NPV) calculations showed that the choice of a carbon steel condenser ensured cash return in a relatively shorter period of time (i.e. 2 years) when compared to a stainless steel condenser (i.e. 5-7 years). Moreover, the NPV for the stainless steel was more sensitive to the change of the interest rate.