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stream can inhibit the extent of cooling possible. Examples include sulfates in glass melting and tars in coke ovens, which increase the complexity of heat recovery at temperatures below 510°F [270°C] and 840°F [450°C], respectively. In addition to temperature constraints, there are practical and economic limitations on heat recovery equipment. For example, larger surface areas required for further recovery will increase capital costs, as well as increase the pressure drop in the flue gas. The increased pressure drop in turn increases requirements for auxiliary power consuming equipment. In other cases, such as cement preheater kilns, structural engineering load limitations prevent additional preheat stages. Additionally, a concern in some combustion air preheat applications is the increase in NOX emissions resulting from higher flame temperatures. This may influence the final design temperatures of the waste heat source and the preheated combustion air. Finally, there may be insufficient enduses available onsite for the recovered waste heat. These factors all contribute to the large quantities of unrecovered waste heat exiting recovery devices. 5.4.2 RD&D Needs for Optimizing Existing Recovery Systems Optimizing Recovery Systems Efforts to improve heat recovery systems encompass many of the same efforts listed in Section 5.3. Development opportunities could involve lowcost solutions that address chemical attack to heat exchanger materials, increase heat transfer efficiency, and enable heat recovery at lowtemperature ranges. Beyond optimizing heat recovery systems to increase the quantity of recovered energy, there are also opportunities to increase the quality of energy recovered. In many hightemperature applications, dilution air is introduced into the waste heat stream in order to protect ducts and heat exchanger materials from damage. Advanced materials are available that can withstand high temperatures; however, typically these are very costly. Most options for recovery of highquality heat will require the availability of lowcost manufacturing technologies for advanced materials for use in hightemperature applications. It is often more economical for facilities to introduce dilution air that reduces the waste heat temperature. In these cases, there is no loss in the quantity of heat in the exhaust stream; however, since the temperature is reduced, it is of lower quality. An alternative to air bleeding is using more advanced alloys and composite materials for heat exchangers and ducts. RD&D that reduces costs of these materials will maximize the efficiency of recovery systems. EndUse Technologies for LowTemperature Heat As discussed in Section 5.3, limitations on available enduse applications for waste heat can prevent heat recovery in a number of cases. Any developments that create alternative enduses for waste heat may increase opportunities for energy efficiency. 5.5 Expanding Heat Recovery in Certain Market Segments 5.5.1 Applications Where Heat Recovery is Less Common Approximately 5,400 TBtu out of the 8,400 TBtu of energy consumption analyzed are consumed in systems that already have some level of waste heat recovery leaving nearly 3,000 TBtu are consumed in systems that are not currently using heat recovery. These systems account for about 540 TBtu of waste heat annually (Table 23). Economiesofscale and processrelated chemicals in exhaust streams are key factors in the decision not to include heat recovery. 58 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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