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Table 18 Unrecovered Waste Heat and Work Potential from Industrial Boiler Exhaust Gases Source Carnot Efficiency Work Potential Assumed Average Exhaust Temperature Waste Heat 77°F [25°C] Ref Waste Heat 300°F [150°C] Ref Energy Consumption Boilers No Recovery With Recovery Conventional Fuels Byproduct Fuels Total 1,625 500 260 348 4,875 2,438 300 150 394 2,438 350 177 428 73 44% 153 30% 117 27 34% 144 TBtu/yr °F °C TBtu/yr TBtu/yr TBtu/yr 6,500 1,170 100 414 Note: Sources and assumptions in Appendix A: Documentation of Waste Heat Estimates The most significant fuel sources for boilers are natural gas (2,141 TBtu/yr) and byproduct fuels (3,249 TBtu/yr). Byproduct fuels include black liquor and wood waste in the paper industry, refinery byproducts (e.g., still gas), and coke oven and blast furnace gases in primary metals manufacturing. Exhaust temperatures will depend on the pressure of steam required for a given industrial process. In this study, average exhaust temperatures are assumed to be around 500°F [260°C] without heat recovery. Heat recovery is quite common for boilers. Options include economizers, air preheaters, or both. Average exhaust temperatures from boiler economizers using conventional fuels are likely to be around 300°F [150°C].138 Meanwhile, boilers burning byproduct fuels (e.g., black liquor) would be likely to have minimum final exhaust temperatures around 350400°F [180200°C].139 Typical efficiencies for natural gas boilers range from 8085%, while boilers firing black liquor have efficiencies as low as 70%.140, 141 According to conversations with boiler manufacturers, most boilers with capacities greater than about 25 million Btu/hr include economizers. Though there are a large number of small boilers in different facilities, total U.S. industrial boiler capacity is dominated by boilers with energy consumption greater than 50 million Btu/hr;142 therefore, the use of economizers can be considered a fairly typical practice. A very small number of facilities also use condensing economizers (Section 3.3.2) to cool exhaust gases to temperatures as low as 100150°F [3866°C], where the latent heat contained in water vapor can be recovered. Boilers incorporating condensation recovery have been commercially available for several decades; however, they are only used in a small fraction of the boiler market. According to a market study of commercial boilers, only about 2% of the boilers sold included condensation recovery.143 Conversations with boiler manufacturers indicate that condensing systems make up a similarly small fraction of the industrial boiler market. A key barrier is the high capital cost of condensing economizers, which can be almost three times as much as a conventional economizer.144 Additionally, it is necessary that return water is at a sufficiently lowtemperature (e.g.,100150°F or [38°66°C]) to enable heat transfer from the exhaust gas to the return water. This is often not available. Exhaust gas waste heat losses from industrial boilers are estimated at about 1,200 TBtu/yr. This is largely lowquality waste heat. Nevertheless, it is noteworthy that because the quantity of heat available is so large, the work potential of this waste heat source is about 400 TBtu, which considerably exceeds the work potential of waste heat exhausted by other highertemperature sources. Considering the large number of industrial boilers (43,000) and the high quantity of energy consumed for steam generation, incremental improvements in boiler efficiency could have an appreciable impact on total energy consumption. It should also be noted that commercial boilers are also significant energy consumers, responsible for another 1,630 TBtu/yr of energy consumption, and responsible for 263 TBtu/yr of low temperature waste heat loss. Any technology improvements that reduce the cost of condensing 48 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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