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sources not typically considered for recovery, and increasing “enduse” options for heat recovery. Moreover, despite the significant environmental and energy savings benefits of waste heat recovery, its implementation depends primarily on the economics and perceived technical risks. Industrial manufacturing facilities will invest in waste heat recovery only when it results in savings that yield a “reasonable” payback period (<< 3 years) and the perceived risks are negligible. A key consideration in any RD&D effort, therefore, should be minimizing economic costs of waste heat recovery technologies. Study Approach This study uses a bottomup approach to identify technology needs in industrial waste heat recovery by characterizing specific, large industrial waste heat streams, describing current recovery practices and barriers, and using these results to identify RD&D needs. The report evaluates unrecovered waste heat from some of the most energyintensive processes in U.S. manufacturing, such as coke ovens and aluminum melting furnaces. The investigation focuses primarily on exhaust streams from high temperature processes since these applications are some of the most significant sources of highquality waste heat. However, during the course of this study, it also became apparent that nonconventional sources of waste heat (e.g., aluminum furnace sidewall losses, losses from heated products, and lower quality waste heat) should also be targeted for research in heat recovery technologies. Each waste heat stream is investigated in terms of its waste heat quantity (the approximate energy contained in the waste heat stream), quality (typical exhaust temperatures), current recovery technologies and practices, and barriers to heat recovery. Energy content of waste heat streams is a function of mass flow rate, composition, and temperature, and was evaluated based on process energy consumption, typical temperatures, and mass balances. The enthalpy of waste heat streams was estimated from two reference (Ref) temperatures: 77°F [25°C] and 300°F [150°C]. Ambient conditions are represented at 77°F [25°C], while 300°F [150°C] represents a common design point used to avoid condensation with many waste gas streams. Since waste heat temperature is an important quality in the feasibility of waste heat recovery, this study reports typical exhaust temperatures of all waste heat sources investigated. Additionally, the work potential or efficiency of converting waste heat to another form of energy (i.e., mechanical or electrical) was estimated. The work potential (based on Carnot efficiency) is a measure of the maximum energy that could be recovered by using the waste heat to drive a heat engine. Quantifying work potential allows a better comparison of waste heat sources with different exhaust temperatures. The potential for heat recovery is further scoped out by discussing current waste heat recovery practices and barriers to heat recovery for each unit assessed. Finally, the results from the bottomup analysis of waste heat sources were used to identify technology development needs for wider implementation of industrial waste heat recovery. Technology needs are discussed in the context of existing technologies, which can be further optimized, as well as developing technologies that may provide new opportunities for heat recovery. Waste Heat Profile This study analyzed selected industrial processes that consume about 8,600 TBtu, or one third of the energy delivered to U.S. industrial facilities.† Investigation of current waste heat recovery practices shows that waste heat is generally recovered from clean, hightemperature waste heat sources in large capacity systems. Key opportunities are available in optimizing existing systems, developing technologies for † Based on 25 quadrillion Btu of energy consumption, which excludes losses associated with electricity generation. US DOE EIA Annual Energy Review 2006. xi PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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