Waste heat recovery from boiler of large-scale textile industry

Updated : October 2020


  • EHS professionals
  • Energy management professionals
  • Machinery and equipment makers
Exhaust gas from the boilers in the textile industry generates a lot of energy that goes to waste if not captured and utilized optimally. This study presents a way to recovery heat waste from boiler exhaust gas using a shell and tube heat exchanger. Exhaust gas from boiler dyeing processes carries a large amount of heat. The waste energy from the same can be decreased by using waste-heat recovery systems. In this study, using ANSYS simulation, a thermodynamic analysis was performed. An energy-based approach was used for optimizing the effective working condition for waste-heat recovery with exhaust gas to air shell and tube heat exchanger. The variations of parameters, which affect the system performance such as, exhaust gas and air temperature, velocity, and mass flow rate, and moisture content are examined respectively. For the experiment, a separate heat exchanger was designed with tubes in which the exhaust gas is allowed to pass through the shell side to achieve a higher surface area on the gas side. The major criterion in the design of a waste heat recovery system is the proper selection of heat exchangers with optimum conditions. Energy and environmental studied show that in the increase of process efficiency, thermal waste from the boiler was reduced. The economic evaluation showed that the payback period of the heat exchanger is approximate 6 months; the Internal Rate of Return (IRR) is 182%.

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Economic evaluation of shell and tube heat exchanger

Variation parameters for process and heat exchanger efficiency

Thermodynamic analysis simulation for textile boilers

Energy optimization techniques in sheel and tube heat exchanger

Operational parametere in boiler dyeing processes

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