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Table A2.18 - Assumptions Used for Calculating Industrial Boiler Exhaust Gas Waste Heat Loss Assumed Fraction of Total Capacity Industrial Boilers No Heat Recoverya 25% With Heat Recoverya 75% Conventional Fuelsb 38% Byproduct Fuels 38% a. Assumes 75% of boiler capacity includes economizers. Based on conversations with boiler manufacturers, economizers are more common for large capacity units (e.g. greater than 25 MM Btu/hr), while less common for smaller capacity units. An ORNL study indicates that U.S. boiler capacity is heavily dominated by large units greater than 50 MM Btu/hr, as shown in Table A 19. (ORNL, 2005, Characterization of the U.S. Industrial/Commercial Boiler Population p. 2-2.). Therefore, 75% was chosen as a reasonable representation of waste heat recovery practice. b. Approximately 1/2 of boilers use byproduct fuels, according to ORNL, p. 2-5. It was assumed that byproduct fuels will require higher final exhaust temperatures compared to conventional fuels. Final temperature estimates for economizers with conventional and byproduct fuels based on BCS, 2006. Engineering Scoping Study of Thermoelectric Generator Packages for Industrial Waste Heat Recovery, p. 28 and Stultz, S, and Kitto, J.B. ed., 1992. Steam: its Generation and Use. Barberton, Ohio: The Babcock & Wilcox Company. p. 26-5. Table A2.19 - Boiler Capacity <10 102,305 10-50 277,810 50-100 243,125 100-250 249,135 >250 616,210 1,488,585 Source: ORNL, 2005, Characterization of the U.S. Industrial/Commercial Boiler Population p. 2-20 Energy Consumption (TBtu/year) 6,500 1,625 500 260 4,875 2,438 300 150 2,438 350 177 Estimates Assumed Average Exhaust Temperature % °F °C Boiler Size (Million Btu/hr) Total Capacity (Million Btu/hr) Percent of Total Capacity 7% 19% 16% 17% 41% 100% A - 21PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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