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other water used for cooling systems. The upper limit is based on several considerations, such as the condensation temperature of combustion products or flue gases (usually below 180°F or 82°C for natural gas combustion products); the applicability of low-temperature, non-oxidizing materials such as aluminum or non-metallic materials such as polymers or plastics; or the usage of low- temperature waste heat recovery systems such as heat pumps. Low temperature: 250°–450°F (or 120°–230°C), as defined in the BCS report. Medium temperature: 450°–1,200°F (or 230°–650°C), as defined in the BCS report. High temperature: >1,200°F (or >650°C), as defined in the BCS report. However, based on contacts with the industry and waste heat recovery equipment suppliers, it is suggested that this range be divided into two temperature ranges. The normal definition of the “high” temperature range, based on availability of equipment and material, is 1,200°–1,600°F (or 650°–870°C). Ultra high temperature: >1,600°F (or >870°C). Waste heat recovery from streams above 1,600°F (870°C) requires use of special high-temperature materials that can be metallic or nonmetallic, such as ceramics. Selection of material and equipment design becomes very critical in many cases, as such streams contain a large amount of contaminants. Other Reports The Lawrence Berkeley National Laboratory Industrial Energy Study group has prepared several reports that describe energy use and energy efficiency improvement opportunities such as the “Energy Efficiency Improvement and Cost Savings Opportunities for Petroleum Refineries: An ENERGY STAR Guide for Energy and Plant Managers.” These reports were published for several industries, including steel, cement, and food processing, and include discussion of waste heat recovery and suggestions on using certain technologies to recover waste energy for industrial processes. A July 2009 report prepared by McKinsey & Company, “Unlocking Energy Efficiency in the U.S. Economy,” examines, in detail, the potential for greater efficiency in non-transportation energy uses and assesses the barriers to this goal. The report suggests formulating an overarching strategy that includes recognizing energy efficiency as an important energy resource, as well as formulating and launching approaches to foster innovation in the development and deployment of next-generation energy efficiency technologies. The report does not provide specific suggestions regarding R&D program areas. In September 2009, an industry-government forum on Energy Intensive Processes was held at the ITP- sponsored “Energy Intensive Processes Workshop.” The goal of the workshop was to collect feedback on ITP’s Energy-Intensive Processes R&D portfolio and strategy, as well as obtain guidance on future efforts. The workshop included a session on waste heat minimization and recovery and discussion on reducing fuel demands of steam boilers and furnaces by utilizing waste heat recovery. Workshop participants were asked to evaluate platforms, R&D focus areas, and project selections, and to provide recommendations on future topic areas. Participants were interested in the following areas of waste heat minimization and recovery: Ultra-high efficiency steam generation, with one project including the “super boiler” High-efficiency process heating equipment, with priority R&D opportunities including the following: o Ultra-high efficiency combustion o Insulation and refractory systems Waste energy recovery, with top R&D opportunities including the following: o Low-temperature heat utilization Industrial Waste Heat Recovery Page 6PDF Image | Industrial Waste Heat Recovery: Potential
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