A recuperator is a special purpose counter-flow

energy recovery Energy recovery includes any technique or method of minimizing the input of energy to an overall system by the exchange of energy from one sub-system of the overall system with another. The energy can be in any form in either subsystem, but mo ...

heat exchanger A heat exchanger is a system used to transfer heat between a source and a working fluid. Heat exchangers are used in both cooling and heating processes. The fluids may be separated by a solid wall to prevent mixing or they may be in direct conta ...

positioned within the supply and exhaust air streams of an air handling system, or in the

exhaust gas Exhaust gas or flue gas is emitted as a result of the combustion of fuels such as natural gas, gasoline (petrol), diesel fuel, fuel oil, biodiesel blends, or coal. According to the type of engine, it is discharged into the atmosphere through an ...

es of an industrial process, in order to recover the

waste heat Waste heat is heat that is produced by a machine, or other process that uses energy, as a byproduct of doing work. All such processes give off some waste heat as a fundamental result of the laws of thermodynamics. Waste heat has lower utilit ...

. Generally, they are used to extract heat from the exhaust and use it to preheat air entering the combustion system. In this way they use waste energy to heat the air, offsetting some of the fuel, and thereby improve the energy efficiency of the system as a whole.

Description

In many types of processes,

combustion Combustion, or burning, is a high-temperature exothermic redox chemical reaction between a fuel (the reductant) and an oxidant, usually atmospheric oxygen, that produces oxidized, often gaseous products, in a mixture termed as smoke. Combus ...

is used to generate heat, and the recuperator serves to recuperate, or reclaim this heat, in order to reuse or recycle it. The term recuperator refers as well to liquid-liquid counterflow heat exchangers used for heat recovery in the chemical and refinery industries and in closed processes such as ammonia-water or LiBr-water absorption refrigeration cycle. Recuperators are often used in association with the burner portion of a

heat engine In thermodynamics and engineering, a heat engine is a system that converts heat to mechanical energy, which can then be used to do mechanical work. It does this by bringing a working substance from a higher state temperature to a lower stat ...

, to increase the overall efficiency. For example, in a

gas turbine A gas turbine, also called a combustion turbine, is a type of continuous flow internal combustion engine. The main parts common to all gas turbine engines form the power-producing part (known as the gas generator or core) and are, in the directio ...

engine, air is compressed, mixed with fuel, which is then burned and used to drive a turbine. The recuperator transfers some of the waste heat in the exhaust to the compressed air, thus preheating it before entering the fuel burner stage. Since the gases have been pre-heated, less fuel is needed to heat the gases up to the turbine inlet temperature. By recovering some of the energy usually lost as waste heat, the recuperator can make a heat engine or gas turbine significantly more efficient.

Energy transfer process

Normally the heat transfer between airstreams provided by the device is termed as "

sensible heat Sensible heat is heat exchanged by a body or thermodynamic system in which the exchange of heat changes the temperature of the body or system, and some macroscopic variables of the body or system, but leaves unchanged certain other macroscopic vari ...

", which is the exchange of energy, or

enthalpy Enthalpy , a property of a thermodynamic system, is the sum of the system's internal energy and the product of its pressure and volume. It is a state function used in many measurements in chemical, biological, and physical systems at a constant ...

, resulting in a change in temperature of the medium (air in this case), but with no change in moisture content. However, if moisture or relative

humidity Humidity is the concentration of water vapor present in the air. Water vapor, the gaseous state of water, is generally invisible to the human eye. Humidity indicates the likelihood for precipitation, dew, or fog to be present. Humidity dep ...

levels in the return air stream are high enough to allow condensation to take place in the device, then this will cause "

latent heat Latent heat (also known as latent energy or heat of transformation) is energy released or absorbed, by a body or a thermodynamic system, during a constant-temperature process — usually a first-order phase transition. Latent heat can be underst ...

" to be released and the heat transfer material will be covered with a film of water. Despite a corresponding absorption of latent heat, as some of the water film is evaporated in the opposite airstream, the water will reduce the

thermal resistance Thermal resistance is a heat property and a measurement of a temperature difference by which an object or material resists a heat flow. Thermal resistance is the reciprocal of thermal conductance. * (Absolute) thermal resistance ''R'' in kelvi ...

of the

boundary layer In physics and fluid mechanics, a boundary layer is the thin layer of fluid in the immediate vicinity of a bounding surface formed by the fluid flowing along the surface. The fluid's interaction with the wall induces a no-slip boundary cond ...

of the heat exchanger material and thus improve the

heat transfer coefficient In thermodynamics, the heat transfer coefficient or film coefficient, or film effectiveness, is the proportionality constant between the heat flux and the thermodynamic driving force for the flow of heat (i.e., the temperature difference, ). ...

of the device, and hence increase efficiency. The energy exchange of such devices now comprises both sensible and latent heat transfer; in addition to a change in temperature, there is also a change in moisture content of the exhaust air stream. However, the film of condensation will also slightly increase pressure drop through the device, and depending upon the spacing of the matrix material, this can increase resistance by up to 30%. If the unit is not laid to falls, and the condensate not allowed to drain properly, this will increase fan energy consumption and reduce the seasonal efficiency of the device.

Use in ventilation systems

In heating, ventilation and air-conditioning systems,

HVAC Heating, ventilation, and air conditioning (HVAC) is the use of various technologies to control the temperature, humidity, and purity of the air in an enclosed space. Its goal is to provide thermal comfort and acceptable indoor air quality. ...

, recuperators are commonly used to re-use waste heat from exhaust air normally expelled to

atmosphere An atmosphere () is a layer of gas or layers of gases that envelop a planet, and is held in place by the gravity of the planetary body. A planet retains an atmosphere when the gravity is great and the temperature of the atmosphere is low. A ...

. Devices typically comprises a series of parallel plates of

aluminium Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. It ha ...

plastic Plastics are a wide range of synthetic or semi-synthetic materials that use polymers as a main ingredient. Their plasticity makes it possible for plastics to be moulded, extruded or pressed into solid objects of various shapes. This adapta ...

stainless steel Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's r ...

, or

synthetic fiber Synthetic fibers or synthetic fibres (in British English; see spelling differences) are fibers made by humans through chemical synthesis, as opposed to natural fibers that are directly derived from living organisms, such as plants (like cotton) ...

copper Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pink ...

alternate pairs of which are enclosed on two sides to form twin sets of ducts at right angles to each other, and which contain the supply and extract air streams. In this manner heat from the exhaust air stream is transferred through the separating plates, and into the supply air stream. Manufacturers claim gross efficiencies of up to 95% depending upon the specification of the unit. The characteristics of this device are attributable to the relationship between the physical size of the unit, in particular the air path distance, and the spacing of the plates. For an equal air pressure drop through the device, a small unit will have a narrower plate spacing and a lower air velocity than a larger unit, but both units may be just as efficient. Because of the cross-flow design of the unit, its physical size will dictate the air path length, and as this increases, heat transfer will increase but pressure drop will also increase, and so plate spacing is increased to reduce pressure drop, but this in turn will reduce heat transfer. As a general rule a recuperator selected for a pressure drop of between will have a good efficiency, while having a small effect on fan power consumption, but will have in turn a higher seasonal efficiency than that for physically smaller, but higher pressure drop recuperator. When heat recovery is not required, it is typical for the device to be bypassed by use of dampers arranged within the ventilation distribution system. Assuming the fans are fitted with inverter speed controls, set to maintain a constant pressure in the ventilation system, then the reduced pressure drop leads to a slowing of the fan motor and thus reducing power consumption, and in turn improves the seasonal efficiency of the system.

Use in metallurgical furnaces

Recuperators have also been used to recover heat from waste gasses to preheat combustion air and fuel for many years by metallic recuperators to reduce energy costs and

carbon footprint A carbon footprint is the total greenhouse gas (GHG) emissions caused by an individual, event, organization, service, place or product, expressed as carbon dioxide equivalent (CO2e). Greenhouse gases, including the carbon-containing gases carbo ...

of operation. Compared to alternatives such as regenerative furnaces, initial costs are lesser, there are no valves to be switching back and forth, there are no induced-draft fans and it does not require a web of gas ducts spread up all over the furnace. Historically the recovery ratios of recuperators compared to regenerative burners were low. However, recent improvements to technology have allowed recuperators to recover 70-80% of the waste heat and pre-heated air up to is now possible.

Gas turbines

Recuperators can be used to increase the efficiency of

gas turbines A gas turbine, also called a combustion turbine, is a type of continuous flow internal combustion engine. The main parts common to all gas turbine engines form the power-producing part (known as the gas generator or core) and are, in the directio ...

for power generation, provided the exhaust gas is hotter than the compressor outlet temperature. The exhaust heat from the turbine is used to pre-heat the air from the compressor before further heating in the combustor, reducing the fuel input required. The larger the temperature difference between turbine out and compressor out, the greater the benefit from the recuperator. Therefore, microturbines (<1 MW), which typically have low pressure ratios, have the most to gain from the use of a recuperator. In practice, a doubling of efficiency is possible through the use of a recuperator. The major practical challenge for a recuperator in microturbine applications is coping with the exhaust gas temperature, which can exceed .

Other types of gas-to-gas heat exchangers

* Heat pipe * Run-around coil * Thermal wheel, or rotary heat exchanger (including enthalpy wheel and desiccant wheel) * Convection recuperator * Radiation recuperator

References

External links

{{Piston engine configurations Energy conservation Energy recovery Engineering thermodynamics Heat exchangers Heat transfer Heating, ventilation, and air conditioning Heating Industrial equipment Low-energy building Mechanical engineering Sustainable building