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TA 6M: Waste Heat Recovery Figure 6.M.4 Waste Heat Losses and Work Potential from Selected Process Exhaust Gases (2002)4 Figure 6.M.4 shows steam boilers divided into conventional fuels (CF) and byproduct fuels (BF). While steam boilers have high total waste heat losses, attributable to the large number of industrial boilers (approximately 43,000 total units) rather than boiler inefficiency. Typical boiler efficiencies (80-85%) are higher than other fired units such as glass furnaces. Heat losses from boilers are in the low temperature range, as evidenced by the low heat content from a 300°F [150°C] reference. Values do not reflect total waste heat losses by industry, but rather the waste heat losses from selected processes. Iron/Steel includes coke ovens, blast furnaces, basic oxygen furnaces, and electric arc furnaces. Aluminum includes primary refining cells and secondary melting furnaces. Metal casting melting includes aluminum reverberatory furnaces, stack melters, and iron cupolas in metal casting facilities. Aluminum includes primary and secondary refining furnaces. This taxonomy provides a useful framework for future estimates; however, a greater understanding of R&D opportunities is revealed if the temperature ranges are expanded. In this Technology Assessment, the temperature ranges have been expanded on both sides (high and low) of the spectrum. This expansion suggests additional R&D is needed in the temperature ranges below 250°F (ultra-low temperature) and higher than 1,600°F (ultra-high temperature), where cost-effective WHR methods or equipment are currently limited. Hence, this technology assessment targets the following five temperature ranges: Ultra-low temperature: below 250°F. An example of the lower temperature for this range is the temperature of a cooling medium such as cooling tower water or other water used for cooling systems. Recovery of the waste heat is affected by factors such as the condensation temperature of combustion products or flue gases (usually below 180°F for natural gas combustion products); the applicability of low-temperature, non-oxidizing materials such as aluminum or non-metallic materials such as polymers or plastics; or the usage of low-temperature WHR systems such as heat pumps. Low temperature: 250°F – 450°F, as defined in the study. Medium temperature: 450°F – 1,200°F, as defined in the study. High temperature: 1,200°F – 1,600°F, a new range for high temperature is proposed in this TA. Based on input from industry experts and WHR equipment suppliers, it is suggested that the study definition of the “high” temperature range (historically all temperatures >1,200°F) be divided in two temperature ranges – high temperature (1,200°F – 1,600°F) and ultra-high temperature (>1,600°F), which are based on distinctions of equipment and materials for use in these ranges. Ultra-high temperature: >1,600°F. A new temperature range is proposed in this TA for WHR from streams above 1,600°F, which require use of special high-temperature materials that can be metallic or nonmetallic, such as ceramics. Selection of material and equipment design becomes critical in many cases, as such streams contain a large amount of contaminants. 7 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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