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6.0 Conclusion This study evaluated technologies and current waste heat recovery practices in a variety of applications: melting furnaces; boilers; coke ovens, blast furnaces, basic oxygen furnaces, and electric arc furnaces in the steel industry; glass melting furnaces, primary and secondary refining furnaces in the aluminum industry; cement kilns; and ethylene furnaces. The equipment evaluated consumes a total of 8,400 TBtu/yr, or about one third of the energy delivered to industrial facilities.† Systems analyzed varied significantly in terms of typical recovery practices. Industrial boilers account for about 70% of the energy analyzed, and these systems typically incorporate heat recovery. Meanwhile, analysis of other processes showed that heat recovery is frequently used with clean gaseous streams in highcapacity furnaces. However, heat recovery is less common in applications that have dirty exhaust streams and/or in small scale applications. Several furnaces continue operating at efficiencies below 50% due to high exhaust temperatures. Additionally, while this study focused on gaseous exhaust streams, it was concluded that alternate sources of waste heat can be significant and require further investigation. Large quantities of lowtemperature waste heat are available in cooling water. Additionally, significant heat is lost from hot equipment surfaces (e.g., aluminum cell sidewalls) and from product streams (e.g., cast steel, blast furnace slag, etc). Waste Heat Losses Energy content of waste streams was evaluated based on reference temperatures of 77°F [25°C] and 300°F [150°C]. Calculations based on a 77°F [25°C] reference reflect maximum heat recoverable by cooling heat streams to atmospheric temperatures. The 300°F [150°C] reference reflects the typical practice of cooling exhaust gases to no less than 300°F (150°C) in order to prevent flue gas condensation. Based on a reference temperature of 77°F [25°C], waste heat losses via sensible and latent heat contained in exhaust gases studied in this report are about 1.5 quadrillion Btu/yr. Only about 160 TBtu/yr are estimated as potentially recoverable energy based on a reference temperature of 300°F [150°C]. Work potential based on Carnot efficiency for energy conversion (mechanical or electrical) was also evaluated in order to better compare waste heat with different exhaust temperatures. Based on a 77°F [25°C] ambient reference temperature, the work potential of all the waste heat studied is about 600 TBtu/yr. Despite the very low Carnot efficiency for lowtemperature energy conversions, about 75% of the work potential is contained in lowtemperature waste heat streams (i.e., at less than 450°F [230°C]). This is a result of the very large mass flow rate of these lowtemperature waste heat streams. Waste Heat Opportunity Areas Based on trends observed in this study, opportunity areas for waste heat recovery can be grouped as follows: • lowtemperature waste heat sources, � • optimization of existing waste heat recovery systems, � • hightemperature systems where heat recovery is less common (chemical composition, material constraints, and cost/economies of scale are key barriers, and • nonfluid sources typically not considered for heat recovery. † Based on 25 quadrillion Btu of energy consumption, which excludes losses associated with electricity generation. US DOE EIA Annual Energy Review 2006. 65 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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