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Energy targeting and process integration of spray dryer with heat recovery systems

机译：热回收系统的喷雾干燥器的能量靶向和工艺整合

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Energy recovery is essential as it reduces fuel cost and pollution due to emission of flue gases. The energy recovery potential can be easily determined by pinch analysis, where individual fluid streams obey mass balance. However, in this paper, pinch analysis based methodology is proposed for energy targeting of evaporative systems such as dryers where the mass balance of individual streams is not possible due to loss of identity of one of the streams (feed) because of evaporation of water content and separation of the solid part. Initially, a spray dryer with a counterflow arrangement is selected to demonstrate the applicability of pinch analysis for targeting of energy requirement considered as the base case. Additionally, three different heat recovery configurations integrated with spray dryers are explored by pinch analysis for energy targeting as: (i) direct heat recovery, (ii) indirect heat recovery, and (iii) hybrid heat recovery systems. Further heat recovery potentials and their effect on the performance of the drying process are evaluated appropriately for different cases based on exhaust gas temperatures. The pinch analysis shows that with decreasing a mass flow rate of supply gases/air, the exhaust losses are also reducing for spray dryer integrated with all configuration of the heat recovery system. For spray dryer with indirect heat recovery configuration, energy-saving potential with and without exhaust gas/air temperature constraint is achieved as 57 and 68%, respectively, for a given illustrative example. Among all configurations, a hybrid heat recovery system with 80% recirculation is having the highest thermal energy saving potential (74%) compared to the base case. Moreover, the reduction in the driving potential of spray dryers for direct and hybrid heat recovery configurations is appropriately analyzed for new as well as retrofitted drying systems. It is observed that the effect of driving potential is insignificant for a lower recirculation ratio. Further, techno-economic analysis reveals that there are substantial energy savings even after considering the driving potential suitably in new and retrofitted spray dryers with heat recovery systems.
机译：能源回收至关重要，因为它会降低由于烟道气排放引起的燃料成本和污染。通过捏分析可以容易地确定能量恢复电位，其中单个流体流遵守质量平衡。然而，在本文中，提出了基于捏合分析的方法，用于蒸发系统的能量靶向，例如干燥器，其中由于蒸发含水量，因此由于液体蒸发而导致单个流的质量平衡是不可能的和固体部分的分离。最初，选择具有逆流布置的喷雾干燥器以证明夹切分析用于瞄准被认为是基本情况的能量需求的适用性。另外，通过针对能量靶向的能量分析，探索与喷雾干燥器一体化的三种不同的热回收配置是：（i）直接热回收，（ii）间接热回收和（iii）混合热回收系统。基于废气温度的不同情况适当地评估进一步的热回收电位及其对干燥过程性能的影响。夹切分析表明，随着供应气体/空气的质量流量/空气的质量流量，排气损失也减少了与热回收系统的所有配置集成的喷雾干燥器。对于具有间接热回收配置的喷雾干燥器，对于给定的说明性示例，分别具有57和68％的节能电位分别为57和68％。在所有配置中，与基本情况相比，具有80％再循环的混合热回收系统具有最高的热节能电位（74％）。此外，适当地分析了用于直接和混合热回收配置的喷雾干燥器的驱动电位的降低，用于新的以及改装的干燥系统。观察到驾驶电位的效果对于较低的再循环率是微不足道的。此外，技术经济分析表明，即使在用热回收系统的新的和改装的喷雾干燥器中适当地考虑到驱动电位，也存在显着的节能。

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