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Waste Heat Management Guidebook Reference WASTE HEAT MANAGEMENT GUIDEBOOK NBS HANDBOOK 121 A11104 T3fiS4fl U.S. DEPARTMENT OF COMMERCE/National Bureau of Standards and FEDERAL ENERGY ADMINISTRATION/Conservation and Environment NATIONAL BUREAU OF STANDARDS The National Bureau of Standards1 was established by an act of Congress March 3, 1901. The Bureau's overall goal is to strengthen and advance the Nation’s science and technology and facilitate their effective application for public benefit. To this end, the Bureau conducts research and provides: (1) a basis for the Nation's physical measurement system, (2) scientific and technological services for industry and government, (3) a technical basis for equity in trade, and (4) technical services to promote public safety. The Bureau consists of the Institute for Basic Standards, the Institute for Materials Research, the Institute for Applied Technology, the Institute for Computer Sciences and Technology, and the Office for Information Programs. THE INSTITUTE FOR BASIC STANDARDS provides the central basis within the United States of a complete and consistent system of physical measurement; coordinates that system with measurement systems of other nations; and furnishes essential services leading to accurate and uniform physical measurements throughout the Nation’s scientific community, industry, and commerce. The Institute consists of the Office of Measurement Services, the Office of Radiation Measurement and the following Center and divisions: Applied Mathematics — Electricity — Mechanics — Heat — Optical Physics — Center for Radiation Research: Nuclear Sciences; Applied Radiation — Laboratory Astrophysics 2 — Cryogenics 2 — Electromagnetics 2 — Time and Frequency 2. THE INSTITUTE FOR MATERIALS RESEARCH conducts materials research leading to improved methods of measurement, standards, and data on the properties of well-characterized materials needed by industry, commerce, educational institutions, and Government; provides advisory and research services to other Government agencies; and develops, produces, and distributes standard reference materials. The Institute consists of the Office of Standard Reference Materials, the Office of Air and Water Measurement, and the following divisions: Analytical Chemistry — Polymers — Metallurgy — Inorganic Materials — Reactor Radiation — Physical Chemistry. THE INSTITUTE FOR APPLIED TECHNOLOGY provides technical services to promote the use of available technology and to facilitate technological innovation in industry and Government; cooperates with public and private organizations leading to the development of technological standards (including mandatory safety standards), codes and methods of test; and provides technical advice and services to Government agencies upon request. The Insti¬ tute consists of the following divisions and Centers: Standards Application and Analysis — Electronic Technology — Center for Consumer Product Technology: Product Systems Analysis; Product Engineering — Center for Building Technology: Structures, Materials, and Life Safety; Building Environment; Technical Evalua¬ tion and Application — Center for Fire Research: Fire Science; Fire Safety Engineering. THE INSTITUTE FOR COMPUTER SCIENCES AND TECHNOLOGY conducts research and provides technical services designed to aid Government agencies in improving cost effec¬ tiveness in the conduct of their programs through the selection, acquisition, and effective utilization of automatic data processing equipment; and serves as the principal focus within the executive branch for the development of Federal standards for automatic data processing equipment, techniques, and computer languages. The Institute consists of the following divisions: Computer Services — Systems and Software — Computer Systems Engineering — Informa¬ tion Technology. THE OFFICE FOR INFORMATION PROGRAMS promotes optimum dissemination and accessibility of scientific information generated within NBS and other agencies of the Federal Government; promotes the development of the National Standard Reference Data System and a system of information analysis centers dealing with the broader aspects of the National Measurement System; provides appropriate services to ensure that the NBS staff has optimum accessibility to the scientific information of the world. The Office consists of the following organizational units: Office of Standard Reference Data — Office of Information Activities — Office of Technical Publications — Library — Office of International Relations — Office of International Standards. 1 Headquarters and Laboratories at Gaithersburg, Maryland, unless otherwise noted; mailing address Washington, D.C. 20234. - Located at Boulder, Colorado 80302. RATIONAL BUREAU OF STANDARDS LIBRARY JUIV14 1980 toot otc ~ Sef./tlSS Waste Heat QC.t Management Guidebook , IES | c.i (r-jLf'fr-OMu-r* fa Edited by jfALntlU^- I* 1) Kenneth G. Kreider and Michael B. McNeil Office of Energy Conservation Center for Building Technology Institute for Applied Technology National Bureau of Standards Washington, D.C. 20234 Sponsored by: Office of Energy Conservation and Environment Federal Energy Administration U.S. DEPARTMENT OF COMMERCE FEDERAL ENERGY ADMINISTRATION Elliot L. Richardson, Secretary Frank G. Zarb, Administrator NATIONAL BUREAU OF STANDARDS ENERGY CONSERVATION AND ENVIRONMENT Ernest Ambler, Acting Director Samuel J. Tuthill, Assistant Administrator Issued February 1977 Library of Congress Cataloging in Publication Data Main entry under title: Waste heat management guidebook. (NBS handbook ; 121) Supt. of Docs, no.: C 13.11:121 1. Heat recovery—Handbooks, manuals, etc. I. Kreider, Kenneth G. II McNeil, Michael Brewer, 1938- III. United States. Federal Energy Administration. IV. United States. National Bureau of Standards. Office of Energy Conservation. V. Series: United States. National Bureau of Standards. Handbook ; 121. TJ260.W3 621.4'02 76-608201 National Bureau of Standards Handbook 121 Nat. Bur. Stand. (U.S.), Handb. 121, 150 pages (Feb. 1977) CODEN: NBSHAP U.S. GOVERNMENT PRINTING OFFICE WASHINGTON: 1976 For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 (Order by SD Catalog No. C13.11:121). Stock No. 003-003-01669- 1 Price $2.75 (Add 25 percent additional for other than U.S. mailing). CONTENTS Page Introduction . 1 Statement of the problem. 1 How to use the guidebook. 2 Chapter 1 Sources and uses of waste heat . 5 Definitions. 5 Sources of waste heat. 5 How to use waste heat. 6 Organizing a waste heat management program. 7 Implementing waste heat management. 7 Waste heat survey form. 8 Chapter 2 Determination of waste heat requirements. 9 First law of thermodynamics. 9 Second law of thermodynamics. 10 Deriving the heat balance. 13 Heat balance on a boiler. 15 Stack gas condensation. 17 Waste heat recovery. 18 Heat recovery in a steel tube furnace. 19 Heat transfer. 22 Chapter 3 Economics of waste heat recovery. 25 Benefits and costs . 26 Partial methods of evaluation . 28 Comprehensive methods for evaluating investment alternatives. 31 Special factors to consider in investment analysis. 38 Application of evaluation methods to different kinds of decisions. 42 Chapter 4 Case studies of successful systems for industrial waste heat recovery. 53 4.1 Waste heat recovery in a glass plant (metallic radiation recuperator). 55 4.2 Waste heat recovery in a rotary forge furnace (recuperator). 61 4.3 Waste heat recovery in a gas company facility (gas to gas regenerator). 67 4.4 Waste heat recovery in a can company (gas to gas regenerator-incinerator). 73 4.5 Waste heat recovery in a rubber plant (heat pipes in series with heat exchangers). 77 4.6 Waste heat recovery in a dairy (space heating using an economizer). 83 4.7 Waste heat recovery in a glass plant (economizer). 89 4.8 Waste heat recovery in the citrus industry (evaporator). 97 4.9 Waste heat recovery in an asphalt roofing plant (boiler). 105 4.10 Waste heat recovery in a food processing plant (hot water heating via air conditioning cycle). Ill 4.11 Waste heat recovery in an electrical firm (hot water generation via electric heat pump) 119 4.12 Waste heat recovery on a dental products plant (heat wheel). 127 4.13 Waste heat recovery in an incineration application (heat wheel). 131 4.14 Waste heat recovery in an automatic transmission plant (radiation recuperator)... 137 Chapter 5 Commercial options in waste heat recovery equipment. 141 Gas to gas heat exchangers . 142 Gas or liquid to liquid regenerators. 150 Waste heat boilers. 150 Gas and vapor expanders. 151 Heat pumps. 152 Summary. 152 iii Page Chapter 6 Instrumentation . 155 Measurement of gas flow rates. 157 Thermometry. 161 Infrared thermograph . 171 Flue gas analysis. 175 Chapter 7 Engineering data for waste heat recovery . 185 Metric-English units conversion tables . 195 Chapter 8 Sources of assistance for designing and installing waste heat systems. 197 Appendix Guide to notation . 199 IV WASTE HEAT MANAGEMENT GUIDEBOOK K. G. Kreider and M. B. McNeil, Editors Sources of waste (i.e., discarded) heat in industrial processes are reviewed, and an overview of off- the-shelf technology available for its use is given. Discussions of waste heat measurement technology and economics are included, as are 14 case studies of successful industrial waste-heat recovery installations. Key words: Boilers; economics; energy conservation; instrumentation; recuperators; waste heat. INTRODUCTION Statement of the Problem overall awareness of the problem and specific management actions, such as those
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