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In addition to economiesofscale and processrelated chemical constituents, challenges to waste heat recovery include lack of available space for retrofit applications and discontinuous furnace operations that create problems with thermal cycling. Additionally, previous experience with failed heat exchanger installations can prevent interest in waste heat recovery. In some cases applicationspecific constraints may not have been addressed in the design of heat recovery systems. This leads to unexpected maintenance costs. In other cases, operator error could have resulted in heat exchanger failure. A facility with previous negative experience with heat recovery may be less likely to replace previous equipment or install new equipment, typically regardless of the cause of the failure. This may be a result of, among other factors, limited industry R&D staff and expertise for post mortem failure analysis. 5.5.2 Research, Development, and Demonstration Needs for Expanding Implementation of Recovery Technologies Reduce Impact of Chemical Composition of Exhaust Gases Efforts to address chemicalrelated barriers to heat recovery include: • development of lowcost heat exchangers with advanced materials that can withstand harsh environments or that can be easily and cost effectively cleaned and maintained, • development of lowcost gas cleanup systems that can operate at elevated temperatures, and • identification of new industrial process concepts that avoid introducing chemical contaminants into exhaust streams. Optimize Economies of Scale Implementation of waste heat recovery by smallscale facilities will require the development of exchangers that minimize associated capital costs and payback periods. New designs to economically scaledown heat recovery equipment may help increase the practice of industrial heat recovery. Additional challenges for smaller operations may be the costs of energy efficiency opportunity evaluations and engineering and design services. Publicly available tools and resources for energy efficiency improvements can aid smallscale facilities in identifying costeffective heat recovery opportunities.† Tackle Other Barriers to Waste Heat Recovery Additional barriers to waste heat recovery include lack of physical space available to incorporate retrofit systems, discontinuous furnace operations that prevent heat recovery, and previous experiences with failed heat recovery. Not much can be done to solve the problem of lack of physical space, although the decreasing costs of increasingly compact equipment might provide options. Discontinuous furnace operations can create problems by damaging heat exchangers due to thermal cycling. Addressing this issue requires lowering the cost of heat exchangers designed to withstand large fluctuations in temperatures. Lastly, the problem of previous negative experiences with heat exchangers can be addressed by proper distribution of success stories and best practice guidance. Resources that publicize industry successes with heat recovery can help mitigate perceived economic and technical risks of heat recovery. Additionally, federally funded post mortem analysis and lessons learned could be obtained and published. † Resources available include the Department of Energy Industrial Technologies Program “Best Practice” resources (http://www1.eere.energy.gov/industry/bestpractices/), as well as Industrial Assessment Centers (http://www.iac.rutgers.edu/) 60 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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