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6000 5000 4000 3000 2000 1000 0 Current Energy Consumption, Waste Heat Losses, and Work Potential from Process with and without Heat Recovery Systems No Heat Recovery Energy Consumption Tbtu/yr Waste Heat, 77°F Ref Waste Heat 300°F Ref Work Potential 77°F Ref Heat Recovery Already in Place Figure 31 Waste Heat Losses and Work Potential from Processes with and without Heat Recovery Note: The category “Heat Recovery in Place” estimates the waste heat enthalpy of gas streams exiting heat recovery equipment currently installed in furnaces, boilers, etc. Table 22 Comparison of Current Units with and without Heat Recovery Heat Recovery Already in Place 5,409.3 935.5 56.5 306.2 No Heat Recovery 3,029.4 542.2 199.9 282.9 While heat recovery systems successfully capture a portion of the waste heat in exhaust gases, additional opportunity remains in the exhaust gases exiting recovery units. Exhaust gases exiting waste heat recovery systems have temperatures ranging anywhere from 250°F [121°C] to 1,800°F [982°C]. As discussed in Section 4, economizers on waste heat boilers have typical exhaust temperatures of 300°F [150°C], fourstage cement preheater kilns have exhaust temperatures around 640°F [340°C], and recuperative glass furnaces have exhaust temperatures around 1,800°F [982°C]. Therefore, significant quantities of unrecovered waste heat are still available. A number of factors prevent more comprehensive recovery of waste heat in existing installations. In the case of relatively clean combustion exhaust gases, typical minimum exhaust temperature limits are about 300°F [150°C], to prevent flue gas condensation. In other cases, processspecific chemicals in the exhaust Work Potential 77°F [25°C] Ref Energy Consumption TBtu/yr Waste Heat, 77°F [25°C] Ref Waste Heat 300°F [150°C] Ref 57 Energy (TBtu/Year)PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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