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Introduction and Background Waste heat in manufacturing is generated from several industrial systems distributed throughout a plant. The largest sources of waste heat for most industries are exhaust and flue gases and heated air from heating systems such as high-temperature gases from burners in process heating; lower temperature gases from heat treating furnaces, dryers, and heaters; and heat from heat exchangers, cooling liquids, and gases. While waste heat in the form of exhaust gases is readily recognized, waste heat can also be found within liquids and solids. Waste heat within liquids includes cooling water, heated wash water, and blow-down water. Solids can be hot products that are discharged after processing or after reactions are complete, or they can be hot by-products from processes or combustion of solid materials. Other less apparent waste heat sources include hot surfaces, steam leaks, and boiler blow-down water. Exhibit 1 shows typical major waste heat sources along with the temperature range and characteristics of the source. Exhibit 1: Temperature Range and Characteristics for Industrial Waste Heat Sources Waste Heat Source Furnace or heating system exhaust gases Gas (combustion) turbine exhaust gases Reciprocating engines Jacket cooling water Exhaust gases (for gas fuels) Hot surfaces Compressor after or inter cooler water Hot products Steam vents or leaks Condensate Emission control devices – thermal oxidizers, etc. Previous Studies Temperature Range °F 600 – 2,000 900 – 1,100 190 – 200 900 – 1,100 150 – 600 100 – 180 200 – 2,500 250 – 600 150 – 500 150 – 1,500 Temperature Range °C 316 – 1,100 480 – 600 90 – 100 480 – 600 65 – 316 38 – 82 100 – 1,370 120 – 316 65 – 260 65 – 816 Cleanliness Varies Clean Clean Mostly clean Clean Clean Mostly clean Mostly clean Clean Mostly clean A number of reports prepared for the Department of Energy (DOE) and other organizations studied sources of waste heat, primarily from industrial heating systems. The scope of these reports varied from estimating losses from various industrial heating systems in Btus per year to reviewing waste heat from various industries and identifying general R&D opportunities. Following is an overview of several waste heat reports that were used as references in this study. Energy Use and Loss Analysis The “Energy Use and Loss Analysis” report, prepared by Energetics Incorporated, describes total energy used by major manufacturing sectors identified by North American Industry Classification System (NAICS) codes, using Manufacturing Energy Consumption Survey (MECS) data published by the Energy Information Agency. The MECS data was used to estimate major areas of energy use in a plant as well as losses from the subsystems, as shown in Exhibit 2. The losses were based on estimated percentages of losses for the major areas of energy use. The loss factors for each area are shown in Exhibit 3. Based on the loss factors and energy use, an estimate was Industrial Waste Heat Recovery Page 1PDF Image | Industrial Waste Heat Recovery: Potential
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