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Recovering industrial waste heat can be achieved via numerous methods. The heat can either be “reused” within the same process or transferred to another process. Ways of reusing heat locally include using combustion exhaust gases to preheat combustion air or feedwater in industrial boilers. By preheating the feedwater before it enters the boiler, the amount of energy required to heat the water to its final temperature is reduced. Alternately, the heat can be transferred to another process; for example, a heat exchanger could be used to transfer heat from combustion exhaust gases to hot air needed for a drying oven. In this manner, the recovered heat can replace fossil energy that would have otherwise been used in the oven. Such methods for recovering waste heat can help facilities significantly reduce their fossil fuel consumption, as well as reduce associated operating costs and pollutant emissions. Typical sources of waste heat and recovery options are listed in Table 1. Table 1 – Examples of Waste Heat Sources and EndUses Waste Heat Sources Uses for Waste Heat • Combustion Exhausts: Glass melting furnace Cement kiln Fume incinerator Aluminum reverberatory furnace Boiler • Process offgases: Steel electric arc furnace Aluminum reverberatory furnace • Cooling water from: Furnaces Air compressors Internal combustion engines • Conductive, convective, and radiative losses from equipment: HallHèroult cells a • Conductive, convective, and radiative losses from heated products: Hot cokes • Combustion air preheating • Boiler feedwater preheating • Load preheating • Power generation • Steam generation for use in: power generation mechanical power process steam • Space heating • Water preheating • Transfer to liquid or gaseous process streams Blast furnace slags a a. Not currently recoverable with existing technology Combustion air preheat can increase furnace efficiency by as much as 50%, as shown in Table 2. Another advantage of waste heat recovery is that it can reduce capacity requirements for facilities’ thermal conversion devices, leading to reductions in capital costs. For example, consider the case of combustion exhaust gases used to heat building air for space heat. In addition to replacing purchased fuels, the recovered waste heat can potentially eliminate the need for additional space heating equipment, thereby reducing capital and overhead costs.1 In addition to the economic benefits of waste heat recovery for the facility, waste heat recovery is a greenhousegasfree source of energy. The U.S. industrial sector consumes about 32 x 1015 Btu/yr, or one third of the energy consumed in the United States. It is likewise responsible for about one third of energy related greenhouse gas emissions.2 Reducing the Nation’s fossil fuel demand will result in accompanying reductions in greenhouse gas emissions. 2PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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