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Exhibit 4: Estimates of Energy Losses for Major Energy Use Areas in Manufacturing Other Electrochemical Motor Systems Fired Heaters & Cooling Steam Systems Facilities 683 TBtu 362 TBtu 2336 TBtu 7279 TBtu 6201 TBtu 1405 TBtu To Processes Generation Losses Distribution Losses Conversion Losses Potential Process Losses 0 1000 2000 3000 4000 5000 6000 7000 *Onsite generated power has been distributed among end-uses and is not included in the total. Source: Energy Use, Loss and Opportunities Analysis: U.S. Manufacturing and Mining, Energetics Incorporated and E3M, 2004. Waste Heat Recovery: Technology and Opportunities in U.S. Industry ITP issued a detailed report prepared by BCS Incorporated titled “Waste Heat Recovery: Technology and Opportunities in U.S. Industry” that provides information on waste heat sources in major industrial sectors; the nature of waste heat; available waste heat recovery equipment currently used by the industry; and research, development, and demonstration (RD&D) needs. The report classifies waste heat sources in three categories: high temperature (>1,200°F or 650°C), medium temperature (450°–1,200°F or 230° - 650°C), and low temperature (<450°F or 230°C). The BCS report provides a waste heat profile that describes the type of waste heat discharged from industrial plants, general observations related to waste heat sources, the nature of waste heat, and waste heat recovery practices. It outlines RD&D opportunities to extend the economic operating range of conventional technologies and conduct RD&D in emerging and novel technologies. The report also identifies uncovered waste heat in different temperature ranges, concluding that the amount of heat wasted above 77°F (or 25°C) reference temperature is 1,478 trillion Btu per year and lowers to 256 trillion Btu per year if the reference temperature is raised to 300°F (or 150°C). This indicates significant heat recovery opportunities in the 77°–300°F (or 25°-150°C) temperature range, which represents more than 80% of the total estimated waste heat and emphasizes the need for R&D in this range. A summary of key RD&D opportunities identified in the BCS report cross-walked against barriers these opportunities address are shown in Exhibit 5. Trillion Btu Industrial Waste Heat Recovery Page 3PDF Image | Industrial Waste Heat Recovery: Potential
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