prototype of heat recovery system for small industries
Industrial waste heat is the energy that is generated when industrial processes run which is not useable and wasted into the environment that causes environmental pollution. This waste heat energy can be recovered by various method which provides us valuable energy source. By recovering the waste he
2025-06-28 16:28:52 - Adil Khan
prototype of heat recovery system for small industries
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryIndustrial waste heat is the energy that is generated when industrial processes run which is not useable and wasted into the environment that causes environmental pollution. This waste heat energy can be recovered by various method which provides us valuable energy source. By recovering the waste heat energy, the overall energy consumption of a plant can be reduced. In this project, we made the prototype of waste heat recovery system we obtained steam by heating the water through combustion. The electric power is generated by using the steam and fed to steam turbine in a controlled operation. The whole process is controlled by microcontroller (Arduino), which send and receive signal from different components that are being used. It becomes a project of electrical power generation with the help of generated steam in the feedback control system.
Project Objectives1.To recover heat loss in industry.
2. To enhance the efficiency of heat recovery system being used in small industry.
3.To reduce cost of heat recovery system.
4. To reduce the auxiliary energy consumption.
5.To reduce monthly billing.
6.To reduce pollution.
7. For commercial use of small industries.
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Project Implementation MethodIn this project two burners and boilers are used, one burner is used for heating one boiler only cylinder (refrigerant) is being used as a boiler.
First boiler is used to store the water and burner is used for heating to produce the steam, while the other boiler is used to store the steam that is produced by the first boiler, temperature sensors are used in both boilers.
These boilers are connected in series so that the pressure which produced by both boilers will be same. Servo actuated valve is used for burning control this valve operates on the value of pressure which is obtained by the optical sensor placed in the analog pressure gauge.
The analog pressure gauge is being used and it is digitalized using optical sensor mount on the gauge to get the values of pressure with the needle movement, these values are used by the Arduino to maintain the desired pressure with the help of mapping command.
The generated steam is fed to steam turbine with the help of servo actuated valve to run the steam turbine at desired speed. (Solenoid valve and servo actuated valve are used for maintaining the desired pressure) these valves are operated on basis of steam turbine and output voltages.
A solenoid valve is being used for safety release purpose it operates at the pressure of 90 psi. Generator is coupled with steam turbine with the help of belt, buck boost converter is used to maintain the desired voltages at the output, three Led lights of 5w is being used as the load. The LCD screen is being used for displaying the values.
1) Increased Efficiency
We are constantly looking for ways to improve efficiency. This is seen from the high efficiency appliances in our homes to the fuel-efficient cars that have been invented. Waste heat recovery systems help to enhance efficiency on a large scale, like in large manufacturing facilities and production plants. With this system a relatively small change can profoundly impact efficiency, on the industry level and the larger scale.
2)Resource Conservation
With the world population at a high, we are consuming resources at a much faster rate than they are being replenished. In such a scenario it is crucial that precious resources be used efficiently and be conserved as much as possible. This responsibility is especially greater for large scale businesses. Sometimes installing a waste heat recovery system can eliminate the need for another source of heat altogether. This has a significant impact to the conservation of energy sources.
3) Waste Reduction
Processes that involve plant heating and manufacturing inevitably result in the production of waste. Some waste is unavoidable, but heat waste can be repurposed instead of discarded. Redirecting waste gas and reusing it as a heat source can reduce the waste produced by a facility and released into the atmosphere.
4) Reduce Plant’s Operating Costs
After repurposing heat from your plant’s operations you can integrate it into your internal processes which will help you meet operational demands. Operational costs will be reduced by using this new energy for applications that require both heating and cooling.
5) Reduce Your Plant’s Energy Consumption
The technology used in a waste heat recovery system enables companies to reduce waste and increase their efficiency. On a plant level, implementing this system can reduce your plant’s energy consumption by a lot. Every unit of captured waste heat directly replaces each unit of purchased energy. Repurposing this energy leads to huge savings in energy costs.
6) Aids in Repurposing Dangerous Emissions
While waste heat recovery can help in saving energy and reducing waste, it is instrumental to handling the dangerous waste generated from industrial processes. The waste gases expelled are often dangerous and toxic. They cannot be released into the atmosphere directly and need to be incinerated first.
1. Fuel savings per year
The project activity is installation of waste heat recovery system for pre heating
combustion of gass and reduces coal consumption.
2. Electricity savings per year
No electrical savings is envisaged by WHR, further, the WHR consumes electricity
consumption for operation of FD fan blower. Total electricity cost would be `2.42 lakh/year.
3. Improvement in product quality
The project activity is installation of waste heat recovery system and doesn?t have impact
on the product quality.
4. Increase in production
The project activity is waste heat recovery system and heat in the flue gases is used for
pre-heating the Refractories and hence reduces the time of the curing. Hence, the
production may improve due to reduction in batch time.
5. Reduction in raw material consumption
No significant effect on the raw materials consumption.
6.Reduction in other losses
Final Deliverable of the Project HW/SW integrated systemCore Industry Energy Other Industries Others Core Technology OthersOther Technologies Augmented & Virtual RealitySustainable Development Goals Good Health and Well-Being for PeopleRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 75000 | |||
| boiler | Equipment | 1 | 12000 | 12000 |
| lpg gass cylinder | Equipment | 1 | 7000 | 7000 |
| burner | Equipment | 1 | 3000 | 3000 |
| Pelton turbine | Equipment | 1 | 17000 | 17000 |
| solenoid valves | Equipment | 2 | 4000 | 8000 |
| dc bettery 12 v | Equipment | 1 | 7000 | 7000 |
| arduino | Equipment | 1 | 5000 | 5000 |
| IR sensor | Equipment | 1 | 4000 | 4000 |
| servo valves | Miscellaneous | 2 | 2000 | 4000 |
| pressure gauge | Equipment | 1 | 3000 | 3000 |
| LCD | Miscellaneous | 2 | 1500 | 3000 |
| Bridge rectifier | Miscellaneous | 1 | 2000 | 2000 |
| copper pipe | Miscellaneous | 0 | 1000 | 0 |