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A few U.S. manufacturers have long used waste energy to great advantage, including the pulp and paper industry—which burns wood bark and other wastes to produce both electricity and useful thermal energy. Still, opportunities to recycle industrial waste energy are vast, varied, and remain largely untapped, even though many of them are fully feasible with well-established technologies. Lawrence Berkeley National Laboratory has estimated that energy recycling represents nearly 100 gigawatts (GW) of untapped electrical capacity (Bailey & Worrell, 2005). This figure is roughly equal to 10% of current U.S. electric capacity (Energy Information Administration, 2009) and, as an alternative electricity source, would reduce carbon dioxide emissions (C02) by nearly 400 million metric tons (Bailey & Worrell, 2005). The recovery and recycling of industrial waste energy fits under the umbrella of “co-generation,” or Combined Heat and Power (CHP). CHP makes use of the fact that great energy efficiencies can be achieved by using one single process to generate both useful heat and electricity. CHP achieves much greater efficiencies than a typical power plant, where two-thirds of the energy used to produce electricity is simply discarded in the form of waste heat. Because the vast majority of U.S. power generation does not use the waste heat that is its by-product, the power sector is only about 34% efficient at best, a figure that has not improved since the 1960s (Oak Ridge National Laboratory, 2008). CHP, in contrast, combines the generation of useful heat and power, achieving efficiencies of 60% to 90%, and even higher in some applications of energy recycling (Sears, 2009). By definition, all CHP constitutes waste heat recovery. To date, most CHP applications have used a fuel source such as natural gas to generate power; thus the recovered waste heat in question is the by-product of electricity generation. By contrast, in CHP projects that recycle industrial waste energy, the waste heat in question (or other waste energy) essentially serves as the “fuel” for electricity generation. In other words, while all forms of CHP drastically improve the energy efficiency of power production, it is worth highlighting this often-overlooked subset of opportunities: those that produce power by recycling existing waste energy that is currently being discarded, requiring no or little additional fossil fuel. Within current CHP, it is difficult to estimate the share specifically attributable to industrial waste energy recycling. There is general agreement, however, that recycled energy is a vast resource. While many firms involved in waste heat recovery have for years been finding creative ways to recycle energy, this niche within CHP has only in recent years begun to be recognized in wider energy policy circles for its important role in energy efficiency. Many important opportunities remain untapped (Sears, 2009). This report focuses on recycling industrial waste energy, with particular emphasis on waste heat and combustible gases. The basic process by which these can be recycled into electricity is shown in Figure 1. Existing waste energy from a manufacturing process that would otherwise be discarded—such as exhaust heat from a blast furnace or off-gases from a coke oven—is 3PDF Image | Carbon-Reducing Technologies and U.S.
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