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Cost-effective thermoelectric or thermo-ionic materials capable of producing electricity from heat with 15%–20% thermal efficiency. Working fluids for low-temperature power generation cycles that can withstand broader temperature ranges for use in ovens and furnaces. Advanced materials to increase temperature lift in absorption cycles and improve overall heating and cooling performance. Catalysts to support lower temperature “reforming” reactions for use in medium- to high- temperature (≥800°F or 430°C) waste heat applications. Higher temperature materials to be used for “bag-houses,” or gas cleaning systems. This will allow use of lower temperature electricity generation cycles. Opportunities in Advanced Concepts and Designs Innovative heat transfer methods and heat exchanger geometries to reduce heat exchanger size (see the Basic Research section). Heat exchangers or regenerators with continuous surface cleaning to remove surface deposits resulting from particulates or fibers in waste gas streams. Air cooled (dry) heat exchangers to be used to replace or supplement currently used water cooled condensers or heat exchangers (see the Basic Research section for heat transfer improvement). New concepts for recovering and collecting heat from gases containing particulates and high- temperature condensable materials as encountered in the glass, steel, cement, and aluminum industries. New regenerator designs to reduce the volume of high-temperature particulate laden gases, such as using a high surface-area-to-volume ratio or high thermal capacity materials that are easy to clean. Improved design of “generator” or waste heat “boilers” that can utilize lower temperature (≥100°F or 37°C) heat source. This allows use of “low grade” waste heat for thermally-activated refrigeration and heat pump systems to replace or supplement direct gas firing. Pumps and turbo-expanders with high turndown capability for use in low-temperature power generation systems. Self-cleaning filters for gases with relatively low particulate loading. Advanced heat exchangers for evaporators and condensers that use direct gas – air heating for the evaporators and air for condensers. Methods to seal ends of a continuous furnace or oven to reduce or eliminate air leaks that result in excessive energy use in heating equipment; increased size for exhaust gas handling systems; and gas treatment, if necessary for meeting local environmental regulations. Opportunities in Sensors and Controls Reliable sensors and controls for high-temperature (>400°F or 200°C) applications to measure and monitor humidity or lower explosion limits (LEL) in dryers and ovens to allow recycling of exhaust gases and reduce the amount of make-up air. Industrial Waste Heat Recovery Page 41PDF Image | Industrial Waste Heat Recovery: Potential
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