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TA 6M: Waste Heat Recovery Engineering Scoping Study of Thermoelectric Generator (TEG) Systems for Industrial Waste Heat Recovery14 The Engineering Scoping Study of Thermoelectric Generator (TEG) Systems for Industrial Waste Heat Recovery14 report evaluated waste heat recovery opportunities for TEG systems in industrial applications, focusing on opportunities in the glass, ethylene, iron and steel, and aluminum industries. Three processes were selected as case studies to explore the potential for TEG waste heat recovery: glass furnaces (905°–2,550°F), aluminum Hall-Hèroult cells (~1,760°F), and reverberatory furnaces (~1,400°F). These applications have high potential for TEG waste heat recovery, as they have high- temperature waste heat discharges and are in many cases poorly suited for conventional fluid-to-fluid heat exchange operations. The study found that: Waste heat recovery systems based on existing TEG materials with a figure of merit (ZT) of ~1 are not generally cost effective for waste heat recovery in industrial applications. Device efficiency rarely exceeds 5% at this level of performance. However, if ZT values could be boosted to ZT=2 or higher, a business case could be made in many industries.15 Energy conversion efficiencies as high as 20% may be possible for TEG systems with a hot-side temperature of at least 1340°F (1000 K) and a ZT value of at least 2. (For further discussion of TEG energy efficiency and materials, see the QTR technology assessment 6.G, Direct Thermal Energy Conversion Materials, Devices, and Systems.) Within the industries considered, an estimated 10 TBtu of energy could be saved annually through the application of TEG technologies with ZT=2. To realize these benefits, key identified R&D needs include the development of advanced thermoelectric materials (with ZT=2 or higher), high-performance heat exchange surfaces, high-heat- flux interface materials, and cost-effective manufacturing techniques for TEG modules. Comments on the Engineering Scoping Study of Thermoelectric Generator (TEG) Systems for Industrial Waste Heat Recovery14 for the purposes of this Technology Assessment: The lack of moving parts in thermoelectric generators holds the promise of reduced operation and maintenance costs and longer times between failures. These potential benefits make thermoelectric generators important to consider for industrial WHR applications. Estimates of energy recovery potential from thermoelectric technologies have varied depending on assumptions. The Direct Thermal Energy Conversion Materials, Systems and Devices Technology Assessment (6.G) estimated a potential savings of 6.5 to 16 TWh of electrical energy annually, which is 0.9 to 2.3% of the 710 TWh of onsite electrical energy used at manufacturing plants (based on 2010 data). This is 1.5–3.7% of the 430 TWh of waste heat predicted for the 2,470 TWh worth of annual industrial energy consumption in the Waste Heat Recovery: Technology and Opportunities in U. S. Industry report.4 The utilization of thermoelectrics for WHR in industrial settings will require not only materials advances to achieve sufficient ZT, but also durable devices with systems and operating costs low enough to provide a return on investment. 10 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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