Investigation of the condensation heat-transfer between the wet air and 3-D finned-tube heat exchanger surface with different anti-corrosion coatings

Improving the energy-saving efficiency of flue gas deep waste heat and reducing the emission of carbon dioxide and other pollutants have been two issues that need to be paid attention to in petrochemical heating furnaces. A hydrogen production reformer with high energy consumption and high carbon emissions in the petroleum refining process affects the thermal and productive efficiency of the hydrogen production, amounts of heat from flue gas are wasted with the exhausted corrosive gas of the reformer, and latent heat is not recovered. To recover the sensible and latent heat from the exhausted gas, a new anti-corrosion, high-efficiency, and low-pressure-drop flue gas condensing heat exchanger (FGCHE) with low consumption and pressure drop was developed. The energy-saving performance was evaluated through on-site measurements and theoretical analysis. The results show that the exhausted gas temperature was reduced from 161.3~175.9 °C to 33.9~38.9 °C after using the new FGCHE to recover waste heat. The energy-saving efficiency and the utilization ratio of flue gas waste heat were 12~16.1% and 74~81.9%, respectively. The latent heat accounted for 41.3~48.1% of the total recovered heat. The exergy efficiency and the total thermal efficiency of the reformer reached 73~86.8% and 95.2~96.6%, respectively. The condensation in the flue gas reduced pollutant emissions (SO2 and NOx). This paper provides a practical application reference for the technology development of waste heat recovery and the application of an FGCHE for petrochemical heating furnaces.

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“…According to the positive balance calculation method, the heat absorption amount of cooling water can be obtained using Equation (11) [40]:…”

Section: Discussionmentioning

confidence: 99%

On-Site Experimental Study on Low-Temperature Deep Waste Heat Recovery of Actual Flue Gas from the Reformer of Hydrogen Production

Wang

Sun

et al. 2023

Sustainability

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“…He et al 15 provided a CHE based on perfluoroalkoxy-based coating that shows good corrosion resistance and thermal conductivity during retrieval. Zhang et al 16 examined three types of CHEs with non-coated blades, pure copper organic coating, and copper organic composite coating. They experimentally examined the effect of the amount of humidity and mass flow rate and temperature of the exhaust gas from the stack and the cooling fluid on the proposed heat exchangers.…”

Section: Introductionmentioning

confidence: 99%

Parametric and economic analysis of condensing heat exchanger combined with organic rankine cycle for heat and water recovery from boiler flue gas

Ghamati

Roudaki

2023

Proceedings of the Institution of Mechanical Engineers, Part A:

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This study concerns with heat and water recovery from the flue gas of a natural gas-fired thermal power plant. A combined system of condensing heat exchanger (CHE) and Organic Rankine Cycle (ORC) is proposed. The CHE acts as the super-heater of the ORC. The flue gas enters to the CHE with a temperature of 160 [Formula: see text] and is cooled to under the water vapor dew point temperature and leads to water vapor condensation, therefore latent and sensible heat are recovered. The condensed water is used as cooling tower make-up water. The ORC refrigerant enters to the CHE as a saturated vapor and is superheated by the recovered heat. In order to achieve the best ORC performance and highest water recovery simultaneously, parametric analysis was done in terms of evaporator and superheating temperature. It was found that by increasing evaporator and superheating temperature, the efficiency and generated power of the ORC increase, although water recovery decreases. Also an increase in evaporator and superheating temperature raises the heat transfer area of CHE, particularly in the non-condensing zone. Therefore to find the optimum evaporation temperature an economic analysis based on NPV method was done and 43°C was determined as the optimum evaporation temperature. Considering this condition, flue gas enters the CHE with a temperature of 160°C and leaves it with a temperature of 57.85°C, and on the other side, the refrigerant enters it in a saturated state and leaves it with a temperature of 75°C. The total area of the CHE is about 39,490 m2. The amount of recovered water is 36.78 kg/s, which saves 34.2 % of the make-up water consumption. Also, the production power of the ORC-CHE was calculated as 24.12 MW and the additional power produced by ORC-CHE compared with bare ORC is 3.97 MW.

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Investigation of self-propelled droplet migration and heat transfer characteristics on non-uniform wettability wedge-patterned surfaces: preparation, characterization, and condensation experiment

Zhang,

Li,

et al. 2024

Chinese Journal of Physics

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Investigation of the condensation heat-transfer between the wet air and 3-D finned-tube heat exchanger surface with different anti-corrosion coatings

Cited by 12 publications

References 22 publications

On-Site Experimental Study on Low-Temperature Deep Waste Heat Recovery of Actual Flue Gas from the Reformer of Hydrogen Production

On-Site Experimental Study on Low-Temperature Deep Waste Heat Recovery of Actual Flue Gas from the Reformer of Hydrogen Production

Parametric and economic analysis of condensing heat exchanger combined with organic rankine cycle for heat and water recovery from boiler flue gas

Investigation of self-propelled droplet migration and heat transfer characteristics on non-uniform wettability wedge-patterned surfaces: preparation, characterization, and condensation experiment

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