Industrial Waste Heat Recovery: Potential

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Industrial Waste Heat Recovery: Potential ( industrial-waste-heat-recovery-potential )

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 Heat transfer systems for gases containing condensable vapors or combustible gases such as solvent vapors in coating ovens. Opportunities for Low-Temperature Waste Heat Sources This section includes two different categories of low temperatures: <250°F (120°C) and 250°–600°F (120°-315°C).  Innovative condensing heat exchangers for gases containing high moisture levels with particulates, as discharged from paper machines, food drying ovens, or other sources.  Nonmetallic materials (polymers) that can withstand condensed water from combustion products containing acid gases. These must be cost competitive and used for low-temperature condensing heat exchangers.  High-efficiency, liquid-gas heat exchangers for low-temperature flue gases or exhaust air from dryers.  Liquid-to-liquid heat exchangers for heat recovery from waste water containing particulates and other contaminants.  Dry coolers for cooling liquids that reduce or eliminate water use in heat exchangers. A special category of heat recovery systems includes use of low- and medium-temperature waste heat for electric power generation and absorption cooling. R&D needs for this category of waste heat recovery systems require further development of components or sub-systems. These developments to enhance performance of the currently used waste to power systems include the following:  Condenser units (heat exchangers) that replace water with air to reduce the cost of cooling towers and liquid cooling systems.  Waste heat exchangers designed for fast startup, low-thermal stresses, low cost, and compact size.  Evaporator section heat exchangers with “de-fouling” for glass and other particle-laden exhaust streams.  Turbo machinery with variable area inlet nozzles for high turndown.  A working fluid pump design with optimized efficiency for vapor compression. The exact design features will vary with the commonly used working fluids used in Rankine cycle systems. The unit may include alternates to the pump design, and could potentially crossover into CO2 compression for sequestration.  Heat recovery recuperators—advanced design and analysis methods to improve thermal stresses for fast startup. R&D Opportunities by Major Industry The following opportunities have been identified where R&D could impact waste heat recovery in the major industries analyzed in this report. Opportunities for the Aluminum Industry  Cleaning high-temperature contaminated gases without cooling them to lower (<570°F or 300°C) temperatures.  Thermoelectric system infrastructure to prepare for higher ZT value materials and for their use in recovering low- to medium-temperature heat, particularly for surface heat losses such as in electrolysis pots. Industrial Waste Heat Recovery Page 36

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