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5.6 Alternate Waste Heat Sources 5.6.1 Waste Heat Losses from Alternate Sources The focus of this study is on exhaust gases from hightemperature processes. However, during the course of this study it became apparent that other sources of waste heat also deserve further investigation into potential heat recovery opportunities. For example, conductive, convective, and radiative sidewall losses from primary aluminum cells (Section 4.4.1) and hot solid streams in the iron and steel industry (Section 4.3) total about 700 TBtu of waste heat (Table 24). This is equal to half of all the waste heat contained in gaseous exhaust streams analyzed in this study (~1.5 quadrillion Btu). Table 24 Waste Heat Losses from Other Sources in Addition to Exhaust Gases Primary aluminum cell sidewall losses 59 41 Solid streams in iron/steel 654 501 Note: Sources and assumptions in Appendix A: Documentation of Waste Heat Estimates 5.6.2 Research, Development, and Demonstration for Heat Recovery from Alternate Waste Heat Sources Heat recovery from solid streams is practiced in only a small number of applications. One challenge with efficiency of recovery from solid streams is that recovery may require additional stages of heat exchange. A common example of heat recovery from solid streams is clinker cooling in cement kilns. Heat in a clinker exiting the kiln is transferred to cooling air, which is then used for combustion air preheat. Coke dry quenching is also implemented in some applications, though it is not very common in the United States. Other methods have been explored such as radiant heat boilers for recovering heat from blast furnace slag and basic oxygen furnace slag, but these have never been commercialized. Research could be done to further investigate waste heat losses from solid streams and opportunities for waste heat recovery. In the case of aluminum sidewall losses, no efforts have been made to recover the heat losses inherent to the HallHèroult manufacturing process. If more efficient methods for aluminum refining cannot be found, perhaps novel methods could be developed for recovering the heat lost through cell walls. For example, thermoelectric or TPV devices could potentially generate electricity from waste heat while frozen cryolite thickness remained constant. In contrast to other RD&D efforts described in this study (which mainly optimize the performance of existing systems), RD&D for nontraditional waste heat sources might require research into new technologies not yet tested in industrial applications. Waste Heat TBtu/yr (77°F/25°C Ref) Work Potential TBtu/yr Waste Heat Source Total 713 541 61 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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