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TA 6M: Waste Heat Recovery Introduction to the Technology/System Introduction to Waste Heat Recovery Waste heat is generated from a variety of industrial systems distributed throughout a manufacturing 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 waste heat sources that are not as apparent include hot surfaces, steam leaks, and boiler blow-down water. Table 6.M.1 shows a number of major sources of industrial waste heat along with the temperature range and characteristics of the source.1 Table 6.M.1 Typical Temperature Range and Characteristics for Industrial Waste Heat Sources1 Waste Heat Source Temperature Range (°F) Cleanliness2 Furnace or heating system exhaust gases Gas (combustion) turbine exhaust gases Reciprocating engines Jacket cooling water Exhaust gases (for gas fuels) Hot surfaces Compressor post-intercooler water Hot products Steam vents or leaks Condensate Emission control devices – thermal oxidizers, etc. 600 – 2,000 900 – 1,100 190 – 200 900 – 1,100 Post-intercooler water 100 – 180 200 – 2,500 250 – 600 150 – 500 150 – 1,500 Varies Clean Clean Mostly clean Clean Clean Mostly clean Mostly clean Clean Mostly clean Various reports prepared for the Department of Energy (DOE) and other organizations1,3,4,5,6,7,8 have studied sources of waste heat, primarily from industrial heating systems. The scope of these reports varied from estimating annual energy losses from industrial heating systems, to reviewing waste heat from various industries and identifying general R&D opportunities. The following is an overview of several waste heat reports that were used as references in this Technology Assessment, with key RDD&D opportunities highlighted that may lead to improved waste heat recovery (WHR). Added to each report overview are comments, considerations and/or updates intended to improve alignment with this Technology Assessment. 2 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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