https://ijmri.de/index.php/jmsi
volume 4, issue 5, 2025
1089
WASTE HEAT UTILIZATION TECHNOLOGIES FOR INDUSTRIAL BOILER
PLANTS
O.Z. Toirov¹, E.T. Juraev², D.O. Hojiev³
¹ ³Tashkent State Technical University, Tashkent, Uzbekistan
²National Research Institute of Renewable Energy Sources
under the Ministry of Energy, Tashkent, Uzbekistan
Abstract:
This article explores modern technological approaches for utilizing waste heat energy
generated during the operation of industrial boiler plants. By recovering significant amounts of
thermal energy typically lost in thermodynamic processes, it is possible to improve energy
efficiency and reuse waste heat as a secondary energy source. Various heat recovery
technologies are analyzed, including heat exchangers, regenerative boilers, waste heat recovery
power generation (WHRPG) based on the Rankine cycle, and absorption chillers. Scientific
studies indicate that reusing waste heat can reduce fuel consumption in industrial boiler plants by
10–30% and significantly cut emissions of harmful gases into the environment.
Keywords:
waste heat, industrial boiler, regeneration, heat exchanger, energy efficiency
Introduction
Improving energy efficiency and reducing emissions are among the most critical challenges in
the energy sector. In many industrial facilities, especially in metallurgy, chemical, oil and gas,
and thermal supply sectors, boilers produce substantial waste heat (i.e., unused high-temperature
exhaust gases, steam, air, or fluids) during operations. This energy is usually lost to the
environment or dissipated through cooling devices.
Scientific studies (Liu et al., 2021; Zhang et al., 2020) show that using special technologies to
recover this heat can significantly reduce energy consumption, improve system efficiency, and
limit environmental damage. This paper presents a technical analysis of waste heat recovery
technologies and their practical applications.
Main Content
1 Sources of Waste Heat
In industrial boiler plants, waste heat originates from:
Flue gases: typically at 150–300°C
Cooled steam or water: typically 70–120°C
Combustion inefficiencies and energy losses
These sources contain substantial unused thermal energy that can be regenerated using advanced
technologies.
2 Waste Heat Recovery Technologies
a)
Heat
Exchangers
Heat exchangers transfer waste heat to working media (e.g., water, air). Common types include:
Tubular heat exchangers
Plate heat exchangers
Regenerative rotary heat exchangers
Studies show that efficient heat exchangers can convert 20–25% of waste heat into useful
thermal energy (Chen et al., 2019).
b)
Waste
Heat
Recovery
Power
Generation
(WHRPG)
WHRPG systems generate electricity from waste heat using the Rankine cycle:
Evaporation of working fluid by waste gases
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volume 4, issue 5, 2025
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Steam drives a turbine
Turbine rotates a generator to produce electricity
These systems are widely applied in cement, steel, and petrochemical industries.
c)
Absorption
Chillers
High-temperature waste heat can be used in absorption cooling systems to produce chilled water
for buildings or industrial processes. Studies (Wang et al., 2022) indicate that such systems can
reduce total energy consumption by 10–15% in industrial boiler applications.
Energy Efficiency and Environmental Benefits
Recovering waste heat leads to:
10–30% reduction in lost thermal energy
3–8% improvement in boiler efficiency
Decreased emissions of SO₂, NOₓ, and CO₂
Reduced fuel consumption and increased economic gain
For example, waste heat recovery systems implemented in China have reduced CO₂ emissions by
up to 100,000 tons annually (Zhou et al., 2021).
Conclusion
Industrial boilers produce significant waste heat during operation. Efficient reuse of this thermal
energy significantly improves boiler system performance. Technologies such as heat exchangers,
WHRPG systems, and absorption chillers not only save energy but also minimize negative
environmental impacts. Continued research on implementing, optimizing, and automating these
technologies offers substantial economic and ecological benefits.
References
1.
Liu, Y., Zhang, H., & Li, C. (2021).
Analysis of Industrial Waste Heat Recovery Systems
in Boiler Plants
. Applied Thermal Engineering, 184, 116159.
2.
Chen, J., Wang, R., & Zhao, Y. (2019).
Performance Evaluation of Heat Exchangers in
Steam Boiler Systems
. Energy Conversion and Management, 183, 287–297.
3.
Wang, Y., Hu, Z., & Zhang, Q. (2022).
Absorption Refrigeration Systems Driven by
Industrial Waste Heat: A Case Study in Chemical Plants
. Renewable Energy, 195, 1058–1067.
4.
Zhang, X., & Zhou, Y. (2020).
Techno-Economic Assessment of Waste Heat Recovery in
Cement Plants
. Energy Reports, 6, 3201–3212.
5.
Zhou, J., et al. (2021).
Environmental Benefits of Waste Heat Power Generation in Steel
Industry
. Journal of Cleaner Production, 278, 123842.
