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chemically corrosive systems, recovering heat from nonfluid heat sources, and recovering low temperature waste heat. Observed trends are described below. • Waste heat recovery systems are frequently implemented, but constrained by factors such as temperature limits and costs of recovery equipment. There are a number of cases where heat recovery equipment is installed, but the quantity of heat recovered does not match the full recovery potential. Key barriers include heat exchanger material limits and costs for extending recovery to lowertemperature and highertemperature regimes. • Most unrecovered waste heat is at low temperatures. The waste heat streams analyzed in this study showed that roughly 60% of unrecovered waste heat is low quality (i.e., at temperatures below 450°F [232°C]). While lowtemperature waste heat has less thermal and economic value than hightemperature heat, it is ubiquitous and available in large quantities. Comparison of total work potential from different waste heat sources showed that the magnitude of lowtemperature waste heat is sufficiently large that it should not be neglected in pursuing RD&D opportunities for waste heat recovery. New technologies are developing that may provide significant opportunities for lowtemperature heat recovery. • There are certain industrial subsectors where heat recovery is less common, due to factors such as heat source’s chemical composition and the economiesofscale required for recovery. Hightemperature, highquality heat is wasted in some subsectors due to corrosive/fouling chemicals contained in the waste heat stream, or due to economiesofscale that limit recovery (e.g., small metal casting and glass operations). • Losses from nontraditional waste heat sources are difficult to recover, but significant. This study focused on exhaust gas waste heat losses; however, it was found that alternate sources of waste heat are also significant. These include heat lost from hot product streams (e.g., hot cast steel) and hot equipment surfaces (e.g., aluminum sidewalls). Heat losses from heated solid streams in the iron and steel industry total 600 TBtu/yr, and losses from primary aluminum cell walls total 45 TBtu/yr. These heat losses alone are about onethird the size of offgas losses from all the processes analyzed in this report. Research, Development, and Demonstration Opportunities: Conventional and Novel Technologies Waste heat recovery technologies, although currently employed to varying degrees at many industrial facilities, face technical and economic barriers that impede their wider application. In order to promote waste heat recovery and process integration, efforts must be undertaken to extend the economic feasibility of conventional recovery technologies, as well as promote new technologies that can be applied to waste heat sources not typically exploited for waste heat recovery. • Extending The Economic Operating Range Of Conventional Technologies Numerous technologies are already well developed for waste heat recovery (e.g., recuperators, regenerators, etc.). However, the challenge is that technologies are not always economical for a given application (e.g., applications with dirty exhaust streams). This report includes an overview of existing technologies and practices and includes summary tables showing the status of technologies in diverse applications. Meanwhile, there are cases where recovery systems are installed, but they operate under constraints which prevent more efficient heat recovery. RD&D xii PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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