Strategy:  All production processes in the world use energy to create a product, and often sizeable quantities of heat is wasted to the environment. This heat could be in flue gas from a heater or furnace, or in a hot fluid requiring cooling before it can be used in the next process step or stored. By analyzing your high temperature processes, possible energy recovery opportunities may be identified.

Application:  CS2 Inc. has helped companies identify opportunities to recover waste heat from high temperature production processes such as the addition of a waste heat steam recovery boiler. One client’s process utilized a high temperature furnace to produce their product with flue gas leaving their process at over 2,500°F. This flue gas was then cooled to below 400°F using a large volume ambient dilution air prior to entry into the air pollution control system (APCS). By installing a waste heat boiler to recover the sensible heat from the hot flue gas, the dilution air could be eliminated that would greatly reduce the gas flow to the APCS and steam which can be used in the process. With our extensive process background and experience with waste heat recovery, we can help develop practical potential savings opportunities for your company.

Potential Cost Savings:  In the application above, the waste heat recovery boiler performs two worthwhile objectives. It cools the flue gas and eliminates the electricity usage for the dilution/cooling air fan, and it generates steam for use in the process that would have otherwise been produced by burning natural gas or fuel oil in a boiler. There is one other serendipitous outcome of the installation of this waste heat boiler, i.e., the reduction in the gas flow to the APCS. Had the boiler been installed initially, the size and cost of the APCS would have been roughly one-third of what was necessary with the dilution air cooling. If the company wanted to expand operations or route other process flue gas to the now oversized APCS, they would have that ability without adding an additional APCS.

CS2 wants to see your company succeed in recovering energy and lowering your energy usage and will do everything we can to assist you.