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Approach 1) Estimate fuel consumption Fuel consumption was estimated based on the approximate energy intensity for different processes (Btu/lb of product), and estimated production values. For example, it is estimated that about 4,500,469 tons of flat glass are produced in regenerative furnaces. These have an average natural gas consumption of about 9 Million Btu/ton (Energetics, Energy and Environmental Profile of the US Glass Industry, p. 56. 2002) Therefore, total fuel consumption for regenerative furnaces in the glass industry is about 38 trillion Btu/year. Energy intensity of processes was determined from a literature review. 2) Estimate exhaust gas chemical composition and mass flow rate Exhaust gas chemical composition The mass fraction xi of each species in the exhaust varies for different processes. In applications involving combustion (the majority of cases considered), exhaust gas is calculated based on the assumed composition of the fuel. Assumed compositions of various fuels are listed in Table A1.1 below. Table A1.1 - Assumed Fuel Composition Coal (mass fraction) Oil (mass fraction) Carbon Hydrogen Sulfur Oxygen Nitrogen Water Ash Source: EPA, 1984. Industrial Waste Heat Recovery and the 72.00% 4.40% 1.60% 3.60% 1.40% 8.00% Carbon Hydrogen Sulfur Oxygen Nitrogen Water 87.30% 12.60% 0.22% 0.04% 0.01% 0.00% Methane (CH4) Ethane (C2H6) Propane C3H8 Butane C4H10 Nitrogen Water Carbon Dioxide Potential for Emissions Reduction 93.27% 3.79% 0.57% 0.29% 1.19% 0.00% 9.00% Ash 0.01% 0.79% The flue gas composition was determined from basic combustion equations. For example, the combustion of methane with 10% excess air is described by: CH4 +1.1*2(O2 +3.76N2)→CO2 +2H2O+0.2O2 +8.272N2 (A6) Similar expressions were written for each species in the fuel (e.g. carbon, hydrogen, etc) to calculate the combustion products. Assuming complete combustion and 10% excess air, the approximate flue gas composition for main fuel types is listed in Table A1.2 below. A-3 Natural Gas (% volume)PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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