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Waste Heat to Energy Tech Opportunities in US Industry

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Waste Heat to Energy Tech Opportunities in US Industry ( waste-heat-energy-tech-opportunities-us-industry )

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5.7 Summary of Key Barriers to Waste Heat Recovery Four opportunity areas for waste heat recovery, each with its concomitant barriers to waste heat recovery, have been discussed. While some of these barriers are specific to the given application, many are cross­ cutting across several heat recovery applications. They reduce the effectiveness of existing heat recovery systems and, in some cases, prevent recovery systems from being installed. In this section, key restrictions are presented by cost, heat stream composition, temperature, process­ and application­specific constraints, and inaccessibility/transportability of certain heat sources. 1) Costs i) Long payback periods ­ Costs of heat recovery equipment, auxiliary systems, and design services lead to long payback periods in certain applications. Additionally, several industry subsectors with high­quality waste heat sources (e.g., metal casting,) are renowned for small profit margins and intense internal competition for limited capital resources. ii) Material constraints and costs ­ Certain applications require advanced and more costly materials. Costly materials are required for high­temperature streams, streams with high chemical activity, and exhaust streams cooled below condensation temperatures. Overall material costs per energy unit recovered increase as larger surface areas are required for more­efficient, lower­temperature heat recovery systems. 2) Economies­of­Scale – Equipment costs favor large­scale heat recovery systems and create challenges for small­scale operations. i) Operation and maintenance costs – Corrosion, scaling and fouling of heat exchange materials lead to higher maintenance costs and lost productivity. 3) Temperature Restrictions i) Lack of an end­use – Many industrial facilities do not have an on­site use for low­temperature heat. Meanwhile, technologies that create end­use options (e.g., low­temperature power generation) are currently less developed and more costly. ii) Material constraints and costs – (a) High temperature – Materials that retain mechanical and chemical properties at high temperatures are costly. Therefore, waste heat is often diluted with outside air to reduce temperatures. This reduces the quality of energy available for recovery. (b) Low temperature – Liquid and solid components can condense as hot streams cool in recovery equipment, leading to corrosive and fouling conditions. The additional cost of materials that can withstand corrosive environments often prevents low­ temperature recovery. (c) Thermal cycling – The heat flow in some industrial processes can vary dramatically and create mechanical and chemical stress in equipment. iii) Heat transfer rates­ Smaller temperature differences between the heat source and heat sink lead to reduced heat transfer rates and require larger surface areas. 4) Chemical Composition i) Temperature restrictions – Waste heat stream chemical compatibility with recovery equipment materials will be limited both at high­ and low­temperatures. ii) Heat transfer rates – Deposition of substances on the recovery equipment surface will reduce heat transfer rates and efficiency. iii) Material constraints and costs – Streams with high chemical activity require more advanced recovery equipment materials to withstand corrosive environments. 62 ­

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