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Executive Summary Industrial energy use in all of its forms (such as fuel, electricity, and steam) accounts for approximately one-third of total U.S energy usage. Energy used in a typical industrial plant is distributed over a large number of subsystems, which can be divided into the following three major categories: Onsite generation of power and other utilities—such as steam, water, and air—that is distributed and used in the plant Process energy use that is distributed over several systems within a plant such as process heating, process cooling and refrigeration, electrochemical, machine drive, and other uses Non-process energy use such as facility heating, ventilating, and air conditioning; lighting; support services; and onsite transportation Energy use analysis indicates that more than 80% of total plant energy usage comes from onsite generation and process energy applications. Onsite generation and process energy uses are also areas of large energy losses; for example, process heating energy losses represent 25%–55% of the total energy use. Almost all losses from onsite generation and process energy applications are lost as heat in many forms—such as sensible and latent heat, radiation, or convection—which is discharged from the system and lost in the ambient. Recovering this waste heat and using it as an energy source in industrial systems is one of the best methods of reducing energy intensity in manufacturing plants. The Department of Energy’s Industrial Technologies Program (ITP) has previously conducted several studies to identify heat losses from industrial energy systems. In addition to using information from those reports, this report explores key sources and characteristics of industrial waste heat and its generation for major industrial sectors, focusing on low-temperature heat in particular. Past studies have indicated that low-temperature waste heat is a large percentage of total industrial waste heat; however, the amount of heat recovered is small compared to the amount of heat recovered from higher temperature sources. The report also discusses barriers and limitations for commonly used and emerging waste heat recovery technologies, with the appendix providing a detailed overview of many technologies and systems currently available and a few emerging technologies under development or in demonstration. Using input from industrial users and waste heat recovery equipment suppliers, where available, information is presented on the performance of and limitations in the use of these technologies and systems. The report also identifies potential research and development (R&D) opportunities. The list of R&D opportunities was based on information gathered from available reports and discussions with industrial users, equipment suppliers, and research workers in the area of industrial waste heat recovery. In the report, R&D opportunities are cross-walked by various temperature ranges, technology areas, and energy-intensive process industries as shown in the following table. R&D Opportunities by Category Heat Source Technology Area Major Industries High-temperature waste heat Medium-temperature waste heat Low-temperature waste heat Basic research Advanced materials Advanced concepts and designs Sensors and controls Advanced high-efficiency power generation Aluminum Cement Chemicals and petroleum refining Coatings Food (snack) manufacturing Glass Iron & steel Paper viiPDF Image | Industrial Waste Heat Recovery: Potential
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