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1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 485 Study & Review of Heat Recovery Systems for SO2 Gas Generation Process in Sugar Industry Mr. Amir K. Deshmukh1, Prof. M. V. Kavade2, Mr. B. Y. Pawar3 1M.Tech student, Department of Mechanical Engineering, R.I.T, Sangli 2Associate Professor, Department of Mechanical Engineering, R.I.T, Sangli 3Head of Instrumentation & Automation Department, S.M.S.M.P Sugar Industry, Akluj ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract- Today the demand of energy is increasing tremendously, but available energy lacks in supply. Hence, there is no option for proper and efficient utilization and conservation of energy. In this paper, the main stress is given on energy conservation by using technique of utilizing waste heat. This paper presents a review of various worksfocusedon waste heat in industry for improving energy efficiency. In the present scenario energy crises is a severe problem across the globe. For the protection of global environment and maintain ecological balance, energy saving is one of the most vitalissue. Therefore, it is essential that we should endeavor for waste heat recovery by making significant and concrete effort. Conservation of energy by waste heat recovery is the need of hour. The different reviews based on the aspects of heat recovery and the methodologies and technologies being employed for its optimization in industries also study through literature. The objective of this work is to hypothetical design of heat recovery system in SO2 gas generation process. I. INTRODUCTION Waste heat is defined as heat which is rejected from the process at a temperature above the ambient temperature to permit the extraction of additional useful energy fromit.The recovery of waste heat is the most beneficial single energy conservation technique which can significantly help to conserve fuel and bring about substantial cost reduction in energy intensive industries. Waste heat is the heat which is produced in a process by combustion of fuel or exothermic chemical reaction and then rejected into the environment even though it can still be utilized for some useful and economic purpose. In most general case, waste heat is the energy associated with the waste streams of air, gases and liquid leaving the boundaries of a plant, section or building and lost to the environment. The strategy of recovery of this heat not only depends on temperature of wasteheatsources but also on the economics involved behind the technology used. Even 1% energy saving in industriesmeansavingoflot of money. Methods of utilization of waste heat: 1. Direct Utilization: For drying or process heating 2. Energy Cascading 3. Cogeneration 4. Recuperators: Shell and Tube, plate, heat exchangers 5. Regenerators: Stationary or rotating type 6. Waste Heat Boilers II. FACTORS AFFECTING WASTE HEAT RECOVERY SYSTEM Following parameters allow for analysis of the quality and quantity of the stream and also provide insight into possible materials/design limitations. For example, corrosionofheat transfer media is of considerable concern in waste heat recovery, even when the quality and quantity of the stream is acceptable. A) Heat Quantity & Quality: The quantity, or heat content, is a measure of how much energy is contained in a waste heat stream, while quality is a measure of the usefulness of the waste heat. B) Waste Stream Composition: Although chemical compositions do notdirectlyinfluencethequalityor quantity of the available heat (unless it has some fuel value), the compositionofthestreamaffectsthe recovery process and material selection. The composition and phase of waste heat streams will determine factors such as thermal conductivityand heat capacity, which will impact heat exchanger effectiveness. C) Minimum Allowable Temperature: The minimum allowable temperature for waste streams is often closely connected with material corrosion problems.Minimum exhaust temperaturesmayalso be constrained by process related chemicals in the exhaust stream; for example, sulphates in exhaust gases from glass melting furnaces will deposit on heat exchanger surfaces at temperatures below about 510ºF [270ºC]. III. REVIEW METHODOLOGY Zhongyi Su [1] carried out the case study on the waste energy utilization in industries at China. He has carried out
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 486 the analysis on the different industrial processesandfinding out huge data for used of organic waste again in the industries. The conclusion of the study shows that reusing the potential wastes for the production is feasible. Liang-Chen Wang [2] carried out the analysis on the reusability of the energy from the exhaust gas calciner for production of carbon. In this study, the analysis of exhaust is done or production of carbon with used of calciner. The present study aims to developthismethodanda combustion model. To demonstrate the correctness of the method and the model, based on the data collected from the working calciners, the energy utilization ratio of a calciner with power of 1250 kW is analyzed. Rakesh Jain [3] Carried outtheperformanceimprovementof a boiler through waste heat recovery from an air conditioning unit. In this study, the heat from the air conditioning unit of the boiler is used for heating the feed water in boiler. The results of the study concluded that efficiency of Boiler will increase from 76.33% to 76.53%. Satish K. Maurya, [4] carried out the work on the analytical study on the waste heat recovery Combined Ejector and Vapour Compression Refrigeration System. The key advantage of the combined plant is the Financial and economical aspects also justify the heat recovery as in most of the cases as in most of the cases returns in term of savings are much greater than the investment costs The paper [5] [6] explained about methods for recovering the heat of flue gases from boilers using heat of vaporization are analyzed. High profitability of the developed thermal circuit involving deep recovery of the heat of flue gases and its storage, as well as good prospects for using it, are demonstrated by a real example in this paper. It conclude that Use of a comprehensive approach for attacking the problem of deeply recovering the heat of boiler flue gases, including heat of vaporizationandinvolvingconsiderationof all elements participating in the heat supply cycle, makes it possible not only to solve this problem technically, but also to optimize the parameters of coolant. D.Kumar and Rao,[7] The results from the energy audit of KOTHAGUDEM Thermal power station, Andhra Pradesh has been presented in this paper. The scope of any energy audit in a thermal power plant should include the studyofthecoal flow, air and flue gas flow, excess air factors and oxygen in the flue gas; study of the heat transfer, effectiveness, proportioning of heat and pressure drop in the heat- exchangers of the water-steam circuit; study of the auxiliary power consumption; the overall performance evaluation such as the gross and the net overall efficiencies, boiler efficiency, boiler feed pump efficiency, air compressor efficiency, evaporation losses and blow down losses of cooling tower etc. Results from such a study at a 500 MW power plant were presented in this report. A detailed analysis of the effect of the fuel on the boiler efficiency, the dry and the wet flue gas loss, combustion characteristics,the start-up and the shut-down losses, the radiation losses and the heat losses due to hydrogen in fuel, moisture in fuel, carbon monoxide in fuel were explained. TABLE 1.1 WASTE SOURCE AND QUALITY In considering the potential for heat recovery, it is useful to note all the possibilities, and gradethewasteheatintermsof potential value as shown in the following Table Sr.no Source Quality 1 Heat in flue gases The higher the temperature, the greater the potential value for heat recovery 2 Heat in vapour streams. As above but when condensed, latent heat also recoverable 3 Convective and radiant heat losess from exterior of equipment Low grade – if collected may be used for space heating or air preheat 4 Heat losses in cooling water Low grade – useful gains if heat is exchanged with incoming fresh water 5 Heat stored in products leaving the process Quality depends upon temperature 6 Heat in gaseous and liquid effluents leaving process. Poor if heavily contaminated and thus requiring alloyheat exchanger. IV. BENEFITS OF HEAT RECOVERY SYSTEM Benefits of ‘waste heat recovery’ can be broadly classified in two categories: Direct Benefits: Recovery of waste heat has a direct effect on the efficiency of the process. This is reflected by reduction in the utility consumption & costs, and process cost. Indirect Benefits: a) Reduction in pollution: A number of toxic combustible wastes such as carbon monoxide gas, sour gas, carbon black off gases, oil sludge, Acrylonitrileandotherplasticchemicals etc, releasing to atmosphere if/when burnt in the incinerators serves dual purpose i.e. recovers heat and reduces the environmental pollution levels. b) Reduction in equipment sizes: Waste heat recovery reduces the fuel consumption, which leads to reduction in the flue gas produced. This resultsinreductionin equipment
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 487 sizes of all flue gas handling equipments such as fans,stacks, ducts, burners, etc. c) Reduction in auxiliary energy consumption: Reduction in equipment sizes gives additional benefits in the form of reduction in auxiliary energy consumptionlikeelectricity for fans, pumps etc. V. PROPOSED RESEARCH WORK The study is carried out on the research based on the waste heat recovery. The based literaturestudyisimplemented for developing the proposed research work. The proposed research work aims for performance analysis of waste heat recovery system for SO2 gas generation process in sugar industry. The fig.1.1 shows the proposed research study model. Fig.1.1: Block diagram of heat recovery system in SO2 gas generation process. The juice clarification is the heart of sugar processing from sugarcane for white consumption sugar. Various clarifying agents are used such as MOL, SO2 gas in this process. The various existing designs of sulphur burner in a plantation of white sugar factory suffer from a number of draw backs including irregular SO2 supply’s, sublimation and incompatibility with automation. These at best are partially continuous and do not ensure supply of SO2 gas in line with the throughput and processrequirement.Thesugarindustry in India therefore has long been insearchofa suitabledesign which is trouble-free and can ensure continuous supply of SO2 gas exactly as per process requirement. Heat recovery of sulphur burner in sugar industry is an important problem both from environmental and economic points of view. The combined heat and power system produces steam that provides heat to sulphur burner where compressed air mixed with sulphur and get SO2 for sulphitation process which is useful for transformation of raw sugar to white sugar. In existing system hot SO2 (400- 5000 c) from sulphur burner is cooled in condenserandthen transformed to the sulphitation process but in this system heat energy of SO2 get wasted. Hence it is decided to implement heat recovery unit for sulphur burner so that system will be economical. CONCLUSION Recovering Waste heat is the need of the day for the industries of developing countries. Extent of literature available shows a continuously increasing interest of researchers, managements and engineers in recovering the heat. Many big industrial plants have already realized the importance of heat recovery andtheyareeffectivelyutilizing it in one or other way. Efforts are being done to improve the recovery efficiencies by using the latest technological advancements and optimization methods. ACKNOWLEDGEMENT We would like to express our gratitude and appreciation to S.M.S.M.P Cooperative sugar industry,Aklujfortheirpositive attitude and guidance which is very helpful for the completion of this paper. REFERENCES [1] Zhongyi Su, Analysis of energyutilizationandwastein China’s processing industry based on a case study, The 7th International ConferenceonAppliedEnergy – ICAE2015, Energy Procedia 75 (2015 ) 572 – 577. [2] Liang-Chen Wang, Analysis of the reusability of the energy of the exhaust gas from the calciner for the production of carbon,Int.J. Energy Science Direct Energy 78 (2014) 439e450. [3] Rakesh Jain, Performance Improvement of a Boiler through Waste Heat Recovery from an Air Conditioning Unit, International Journal ofInnovative Research in Science, Engineering and TechnologyVol. 2, Issue 2, February 2013. [4] Satish K. Maurya,carried , analytical study on the waste heat recovery Combined Ejector And Vapour Compression Refrigeration System, International Journal of Engineering Sciences & Research Technology [1422-1425] [5] A.D.Kiosova, G.D.Avrutskiib, Deep Recovering and Storing of the Heat of Flue Gases from Boilers, ISSN 0040-6015, Thermal Engineering., 58(2), 2011, 948- 952. [6] Prateep Pattanapunt, Kanokorn Hussaro, Tika Bunnakand, Waste Heat Recovery From Boiler Of
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 11 | Nov -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 488 Large-Scale Textile Industry, American Journal of Environmental Science, 9(3), 2013, 231-239. [7] Rukkumani V, Khavya S and Madhumithra S, “Chemical process control in sugar manufacturing unit” International Journal of AdvancesinEngineering & Technology (2014) 2732-2738. [8] Sreyasi Bandyopadhyaya and Santanu Bandyopadhyay, “Design of Heat Recovery Equipments in Sulfur Recovery Unit” Research Gate. First Indo-US Joint Conference of IICHE (2004) 233- 241 [9] A. Sahoo, T.K. Radhakrishnan and C. Sankar Rao, “Modeling and control of a real time shell and tube heat exchanger” ScienceDirect. Resource-Efficient Technologies 3 (2017) 124–132 [10]M.F Remelia, K.Verojporna and B.Singh, “PassiveHeat Recovery System using Combination of Heat Pipe and Thermoelectric Generator” ScienceDirect. Energy Procedia 75 ( 2015 ) 608 – 614. [11]Jaume Gasia, Jan Diriken and Malcolm Bourke, “Comparative study of the thermal performance of four different shell-and-tube heat exchangers used as latent heat thermal energy storage systems” Elsevier. Renewable Energy 114 (2017) 934-944
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