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TA 6M: Waste Heat Recovery Comments on the report Energy Use, Loss, and Opportunities Analysis3 for the purposes of this Technology Assessment: This report provides estimates of energy losses for major energy use areas in manufacturing facilities. It evaluated a limited number of process systems, and indicated that the major energy losses take place in process heaters (includes steam and direct heaters), motor driven systems (compressed air, pumps, and fans), and steam generation systems. More efficient systems can avoid some of these losses. It is important to note that energy losses do not equate to recoverable energy. There are practical limits (technical and economic) with respect to the recovery potential of those losses. The factors impacting the feasibility of WHR options include heat quantity, heat temperature (quality), composition, minimum allowed temperature, and logistical constraints like operating schedules and availability. Depending on these factors, waste heat can have a number of uses including combustion air preheating, boiler feedwater preheating, load preheating, power generation, steam generation, space heating, water preheating, and transfer to liquid or gaseous process streams.4 The energy loss factors for major energy systems used in this report have been updated and refined in the latest energy footprints assumptions/definitions document released in 2014.9 The updated and refined energy loss factors are provided in Table 6.M.3 below. Figure 6.M.2 shows these onsite losses across different industrial systems, including onsite generation losses, onsite distribution losses, and end use losses. Applied energy (applied toward direct production or end use at the plant) is also shown, determined by subtracting from the offsite generation and transmission losses, onsite generation and distribution losses, and end use losses from the primary energy consumption for the facility. These loss factors are represented visually in the DOE Manufacturing Energy and Carbon Footprints, which map energy use and carbon emissions in manufacturing from energy supply to end use.10 By combining energy consumption data with energy loss factors, each footprint visualizes the flow of energy (in the form of fuel, electricity, or steam) to major end uses in manufacturing, including boilers, power generators, process heaters, process coolers, machine-driven equipment, facility HVAC, and lighting.11 For more details, including references, please refer to Table 1 in the “2010 Manufacturing Energy and Carbon Footprints: Definitions and Assumptions” document.9 In addition, Appendix F of the 2013 report U.S. Manufacturing Energy Use and Greenhouse Gas Emissions Analysis12 provides a detailed examination of the methodology used to determine process heating losses shown below in Table 6.M.3. 4 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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