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4.0 Evaluating Selected Applications for Waste Heat Opportunities and Practices Multiple energyintensive processes were investigated in order to identify recovery practices and quantity of unrecovered waste heat. Processes selected for evaluation in this study were chosen by focusing on the most energyintensive industries (e.g., glass, cement, iron/steel) and identifying some of the largest energyconsuming processes. This investigation helped highlight trends in waste heat losses and opportunity areas for waste heat recovery. For each process analyzed, waste heat quantity was evaluated by estimating the typical percent of energy inputs lost to flue gas waste heat, estimating total energy consumed by that process in the United States, and then calculating approximate total waste heat losses from that application. The percent of waste heat loss varies for different furnaces, depending on the flue gas composition and exhaust temperature. In many cases, the processes analyzed already include waste heat recovery. In these cases, efforts were made to estimate the fraction of production currently using waste heat recovery. In cases where heat recovery is already in place, estimates of waste heat evaluate the heat contained in flue gases exiting the recovery device. Therefore, this study only evaluates the unrecovered waste heat. The basis for waste heat calculations and documentation of waste heat estimates are provided in Appendix A. In general, estimates of waste heat loss in exhaust gases were based on estimated fuel consumption and expected specific enthalpy (Btu/lb) of exhaust streams, which depends on temperature and chemical composition of the exhaust stream. Waste heat loss in a given application can be expressed as: Equation (6) where öex is the exhaust gas waste heat, mex is the exhaust gas mass flow rate, xi is the mass fraction of each species in the exhaust gas, and hi(t) is the enthalpy of each species i in the exhaust at the exhaust temperature. Enthalpy is not an absolute term, but must be measured against a reference state (for example, the enthalpy of a substance at room temperature and atmospheric pressure). In this report, the enthalpy of waste heat streams is calculated at two reference temperatures: 77°F [25°C] and 300°F [150°C]. A reference of 77°F [25°C] was used to provide a basis for estimating the maximum heat attainable if a gas is cooled to ambient temperatures. Meanwhile, a reference of 300°F [150°C] was also used, since the majority of industrial heat recovery systems do not cool below this temperature. In addition to evaluating the quantity of waste heat, the work potential was also estimated. The work potential is the maximum work that could be obtained by using the waste heat to drive a heat engine. The work potential is given by: Equation (7) where TH is the waste heat temperature, and TO is the atmospheric temperature (assumed here to be 77°F, [25°C]). An overview of industryspecific recovery practices and estimated heat losses is contained in the sections below. •••∑ Eex =mh(t) =mex (xihi(t))ex ex i •T• WP=ηE=1− o E T H 33 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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