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efforts could further optimize existing technologies to better meet various challenges presented by industry. • Conducting RD&D In Emerging And Novel Technologies New and developing technologies offer promise in recovering waste heat more efficiently and from nontraditional sources. For example, recently developed recovery technology such as the Kalina cycle has proven successful for recovering low to mediumtemperature waste heat. Efforts are also underway to demonstrate compact membrane condensers, which could enhance recovery of latent heat in exhaust gases. Meanwhile RD&D efforts are exploring direct conversion technologies such as thermoelectric generation. Finally, there may be opportunities for new technologies that could recover heat from sources not typically considered for heat recovery (e.g., losses from heated product streams and sidewall losses in aluminum cells). Barriers and Research, Development, and Demonstration Needs Identified for Promoting Waste Heat Recovery Practices Numerous barriers impact the economy and effectiveness of heat recovery equipment and impede their wider installation. Many of these barriers, described below, are interrelated, but can generally be categorized as related to cost, temperature restrictions, chemical composition, application specifics, and inaccessibility/transportability of heat sources. 1.) Costs a. Long Payback Periods Costs of heat recovery equipment, auxiliary systems, and design services lead to long payback periods in certain applications. Additionally, several industry subsectors with highquality waste heat sources (e.g., metal casting) are renowned for small profit margins and intense internal competition for limited capital resources. b. Material Constraints and Costs Certain applications require advanced and more costly materials. These materials are required for hightemperature streams, streams with high chemical activity, and exhaust streams cooled below condensation temperatures. Overall material costs per energy unit recovered increase as larger surface areas are required for more efficient, lowertemperature heat recovery systems. c. EconomiesofScale Equipment costs favor largescale heat recovery systems and create challenges for smallscale operations. d. Operation and Maintenance Costs Corrosion, scaling, and fouling of heat exchange materials lead to higher maintenance costs and lost productivity. 2.) Temperature Restrictions a. Lack of a Viable EndUse Many industrial facilities do not have an onsite use for low temperature heat. Meanwhile, technologies that create enduse options (e.g., lowtemperature power generation) are currently less developed and more costly. b. Material Constraints and Costs i. High temperature Materials that retain mechanical and chemical properties at high temperatures are costly. Therefore, waste heat is often quickly diluted with outside air to reduce temperatures.Thisreducesthequalityofenergyavailableforrecovery. ii. Low temperature Liquid and solid components can condense as hot streams cool in recovery equipment. This leads to corrosive and fouling conditions. The additional cost of materials that can withstand corrosive environments often prevents lowtemperature recovery. iii. Thermal cycling The heat flow in some industrial processes can vary dramatically and create mechanical and chemical stress in equipment. xiii PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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