Advanced flash exhaust heat recovery
Waste heat is extracted in two stages from the exhaust ( 20 ) of a biomass dryer ( 14 ) in a grain alcohol plant ( 10 ). A boiler circuit ( 56 ) provides a first steam at high pressure. A first energy recovery circuit ( 36 ) extracts heat from the exhaust via a non-contact heat exchanger ( 24 ) and provides a second, relatively lower pressure steam ( 78 ), thereby bypassing a portion of the boiler circuit. Working fluids in the boiler and first energy recovery circuits are maintained within boiler water quality specifications and are intermixed to allow the production of the second steam without a pressure reduction device. A second energy recovery circuit ( 44 ) extracts heat from the exhaust downstream of the first energy recovery circuit using a direct contact heat exchanger ( 38 ) and provides a non-boiler quality heated fluid ( 52 ), which may be a heated liquid or a third steam.
1. A method for recovering energy from an exhaust gas produced by a dryer in a grain alcohol plant, the method comprising the steps of:
producing a first steam in a boiler circuit of the plant for a first use in the plant;
extracting heat from the exhaust gas with a first energy recovery circuit comprising a non-contact heat exchanger;
intermixing a portion of the first steam of the boiler circuit and a flash vapor from the first energy recovery circuit to produce a second steam for a second use in the plant, the second steam having a pressure lower than a pressure of the first steam; and
utilizing a second energy recovery circuit comprising a direct contact heat exchanger disposed downstream of the non-contact heat exchanger in a flow path of the exhaust gas to provide a heated fluid for a third use in the plant.
2. The method of claim 1 , further comprising:
producing the flash vapor in a flash vessel receiving a heated working liquid from the non-contact heat exchanger; and
intermixing the portion of the first steam and the flash vapor in a thermocompressor to produce the second steam.
3. The method of claim 2 , further comprising providing makeup fluid to the flash vessel sourced from the boiler circuit.
4. The method of claim 2 , directing blowdown from the flash vessel to a boiler feed vessel of the boiler circuit.
5. The method of claim 1 , further comprising saturating the exhaust gas with water vapor in a wet scrubber disposed between the dryer and the non-contact heat exchanger.
6. The method of claim 5 , further comprising delivering condensate from the non-contact heat exchanger to the wet scrubber.
7. The method of claim 1 , further comprising controlling a pressure of the exhaust gas in the non-contact heat exchanger by cooperatively operating a pressure increasing device disposed in a flow path of the exhaust gas upstream of the non-contact heat exchanger and a pressure control device disposed in the flow path of the exhaust gas downstream of the non-contact heat exchanger.
8. The method of claim 1 , wherein the flash vapor is a first flash vapor, and further comprising producing the heated fluid by:
producing a second flash vapor in a flash vessel receiving heated condensate from the direct contact heat exchanger; and
intermixing a portion of the first steam and the second flash vapor in a thermocompressor to produce the heated fluid as a third steam.
9. The method of claim 8 , further comprising directing the second steam to a side stripper of the plant.
10. The method of claim 8 , further comprising using the third steam to heat at least one of a beer column and a corn slurry in the plant.
11. The method of claim 1 , further comprising producing the heated fluid as heated process water by heating process water from the plant in a preheater using heated condensate received from the direct contact heat exchanger.
12. The method of claim 1 , wherein the grain alcohol plant is a corn ethanol plant.