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TA 6M: Waste Heat Recovery Energy Use, Loss, and Opportunities Analysis3 The Energy Use, Loss, and Opportunities Analysis report3 describes total energy used by major manufacturing sectors identified by North American Industry Classification System (NAICS) codes, using Manufacturing Energy Consumption Survey (MECS) data published by the U.S. Energy Information Administration (EIA) that were available at the time the report was prepared. MECS data were used to estimate plant energy use for major function areas, as shown Figure 6.M.1, along with associated subsystem losses. Subsystem losses were determined by applying equipment loss factors Figure 6.M.1 Major Areas of Energy Use in a Manufacturing Plant3 Energy to the energy used in selected functional categories within the major energy consuming systems, as shown in Table 6.M.2, including some that generate waste heat. Five of the twenty energy savings opportunities identified in the report were WHR opportunities within the plant boundaries. These include WHR from: (1) gases and liquids in chemicals, Export Fossil Energy Supply Utility/ Power Plant Energy Recycle Facilities/HVAC/ Lighting Solar/Geo- thermal/Wind Energy Energy Losses Inside Plant Boundary Energy Losses Table 6.M.2 Typical Energy Losses for Major Energy Systems in a Manufacturing Plant (1998)3 Steam systems (generation + distribution) Power generation Energy distribution (except steam) Energy conversion Motor systems 30% - 35% 24% - 45% ~ 3% 10% – 50% 30% – 80% 2,220 TBtu 270 TBtu 340 TBtu 2,860 TBtu 1,120 TBtu Plant Operation/System Process Energy System Process Energy Systems Process Energy Use Energy Supply Central Energy Generation/ Utilities Energy Distribution Energy Conversion petroleum, and forest products, including hot gas cleanup and dehydration of liquid waste streams; (2) drying processes; (3) gases in metals and non-metallic minerals manufacture (excluding calcining), including hot gas cleanup; (4) calcining (not flue gases); and (5) metal quenching/cooling. TBD Industrial Plant Boundary Energy System Percent Energy Lost Estimated Annual Energy Loss 3 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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