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Table 2 Furnace Efficiency Increases with Combustion Air Preheat Combustion Air Preheat Temperature 400°F [204°C] 600°F [316°C] 800°F [427°C] 1,000°F [538°C] 1,200°F [649°C] Furnace Outlet Temperature 2,600°F [1,427°C] 2,400°F [1,316°C] 2,200°F [1,204°C] 2,000°F [1,093°C] 1,800°F [982°C] 1,600°F [871°C] 1,400°F [760°C] Source: EPA 2003, Wise Rules for Energy Efficiency. Based on a natural gas furnace with 10% excess air. 1.2 Need for This Study The purpose of this report is to identify RD&D efforts required to expand waste heat recovery practices across the U.S. industrial sector. Numerous sources indicate a significant percentage (2050%) of industrial energy inputs is lost as waste heat, totaling anywhere from 5 to 13 quadrillion Btu/yr.† However, there is a dire lack of information on the source of the largest waste heat losses in different sectors and processes and the nature of different waste heat sources (e.g., the waste heat quality and chemical composition) — knowledge of these factors is critical in determining the feasibility and extent of opportunity for waste heat recovery. This study identifies RD&D needs built on a thorough investigation of waste heat losses and barriers across various energyintensive processes/equipment. Previous analysis of nationwide waste heat losses includes studies by Energetics,3 PNNL,4 EPA,5 and Cooke6 (Table 3). The Energetics study conducted in 2004 evaluates energy losses at multiple stages of manufacturing. It does not quantify waste heat losses, but acknowledges that these losses may total 20 50% of energy delivered to plants. The study also uses rough approximations of efficiency improvement opportunities to estimate that 1.6 quadrillion Btu/yr could be saved through various heat recovery efforts.‡ PNNL also conducted a study in 2006 that included estimates of chemical energy in waste heat streams (e.g., the chemical energy of uncombusted CO, CH4, etc.). Another study by EPA in 1984 used stack temperature databases to estimate waste heat losses; limitations of that study include that final exhaust temperatures were lower than furnace exit temperatures, and that the study was conducted over 20 years ago. This study further expands on previous studies by a) evaluating applicationspecific waste heat losses and recovery practices, and b) evaluating the quality/work potential of waste heat. † Based on 25 quadrillion Btu of energy consumption, which excludes losses associated with electricity generation. US DOE EIA Annual Energy Review 2006. ‡ Energetics 2004, p. 72 Energy saving potential includes chemicals, petroleum, and forest product industries (851 TBtu), drying processes (377 TBtu), metals and nonmetallic minerals manufacture (235 TBtu), calcining (74 TBtu), and metal quenching/cooling (57 TBtu). 22% 30% 18% 26% 16% 23% 14% 20% 13% 19% 11% 17% 37% 43% 48% 33% 38% 43% 29% 34% 39% 26% 31% 36% 24% 29% 33% 22% 26% 30% 10% 16% 20% 25% 28% 3PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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