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1.0 Introduction Industrial waste heat refers to energy that is generated in industrial processes without being put to practical use. Sources of waste heat include hot combustion gases discharged to the atmosphere, heated products exiting industrial processes, and heat transfer from hot equipment surfaces. The exact quantity of industrial waste heat is poorly quantified, but various studies have estimated that as much as 20 to 50% of industrial energy consumption is ultimately discharged as waste heat. While some waste heat losses from industrial processes are inevitable, facilities can reduce these losses by improving equipment efficiency or installing waste heat recovery technologies. Waste heat recovery entails capturing and reusing the waste heat in industrial processes for heating or for generating mechanical or electrical work. Example uses for waste heat include generating electricity, preheating combustion air, preheating furnace loads, absorption cooling, and space heating. Heat recovery technologies frequently reduce the operating costs for facilities by increasing their energy productivity. Many recovery technologies are already well developed and technically proven; however, there are numerous applications where heat is not recovered due to a combination of market and technical barriers. As discussed below, various sources indicate that there may be significant opportunities for improving industrial energy efficiency through waste heat recovery. A comprehensive investigation of waste heat losses, recovery practices, and barriers is required in order to better identify heat recovery opportunities and technology needs. Such an analysis can aid decision makers in identifying research priorities for promoting industrial energy efficiency. The objectives of this report are as follows: • provide an overview of conventional and developing heat recovery technologies in the United States and abroad, • evaluate the quantity and quality (temperature) of key industrial waste heat sources, • describe current waste heat recovery practices in different applications, • identify barriers to waste heat recovery, and • suggest Research, Development, and Demonstration (RD&D) efforts that can further promote heat recovery practices. 1.1 What is Waste Heat Recovery? Waste heat losses arise both from equipment inefficiencies and from thermodynamic limitations on equipment and processes. For example, consider reverberatory furnaces frequently used in aluminum melting operations. Exhaust gases immediately leaving the furnace can have temperatures as high as 2,2002,400°F [1,2001,300°C]. Consequently, these gases have highheat content, carrying away as much as 60% of furnace energy inputs. Efforts can be made to design more energyefficient reverberatory furnaces with better heat transfer and lower exhaust temperatures; however, the laws of thermodynamics place a lower limit on the temperature of exhaust gases. Since heat exchange involves energy transfer from a hightemperature source to a lowertemperature sink, the combustion gas temperature must always exceed the molten aluminum temperature in order to facilitate aluminum melting. The gas temperature in the furnace will never decrease below the temperature of the molten aluminum, since this would violate the second law of thermodynamics. Therefore, the minimum possible temperature of combustion gases immediately exiting an aluminum reverberatory furnace corresponds to the aluminum pouring point temperature 1,2001,380°F [650750°C]. In this scenario, at least 40% of the energy input to the furnace is still lost as waste heat (Appendix A: Documentation of Waste Heat Estimates). 1PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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