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TA 6M: Waste Heat Recovery Opportunities in Advanced High Efficiency Power Generation Systems R&D opportunities in advanced high efficiency power generation systems include: High turndown systems for use in applications where the waste heat stream heat content (in terms of Btu/hr) changes significantly (due to mass flow or temperature fluctuations). Systems with non-water cooled condensers to avoid the need for water and cooling towers. Risk, Uncertainty and Other Considerations WHR has the potential to save energy costs, but industry may be reluctant to adopt WHR technologies if there is a perceived or real potential for the technologies to negatively impact production. In order to reduce risk, a comprehensive evaluation of WHR technologies is needed on a case-by-case basis; however, some general guidelines and considerations include: Identify waste heat sources and reduce generation of waste heat. This is the most cost effective and quickest way to reduce energy use and improve overall thermal efficiency of a heating system. Select appropriate methods of heat recycling where the waste heat is used within the heating system itself. Waste heat recycling is the use of waste heat from a process heating system for its use within the same system. This would eliminate issues related to matching of supply and demand of heat. The most commonly used method of waste heat recycling for fuel fired systems is to preheat combustion air where the flue gas temperature is relatively high – usually higher than 1000°F. However, preheating of makeup air or dilution air should be considered at all temperatures for processes using high volumes of air, as in the case of drying ovens. Possibility of load or charge preheating should be considered for new equipment and where available space and system configuration allows its use. A few examples of charge preheating include feed water heating for boilers, and drying and preheating of materials in metals and non-metal industries. If heat recycling is not possible then consider WHR within the plant. Common examples are: use of hot gases in lower temperature processes, to preheat water or cleaning liquids used in the plant, use of heat for space heating in plants located in colder climates, steam generation where waste heat streams contain large (>10 MM Btu/hr) amounts of recoverable heat. Consider use of electric power generation using steam turbine-generator systems or other systems such as organic Rankine Cycle (ORC) systems when it is not possible to use heat within the plant or there is a strong case based on economics to use on-site power generation. Evaluate waste heat characteristics such as temperature, flow rates, waste gas, presence of contaminants (solids, liquid vapors, and other condensable materials), and variations in in these characteristics. Evaluate the overall economics of the waste heat recycling or recovery system. The uptake of WHR technologies is highly dependent upon the willingness of industrial subsectors to invest in technologies that can provide a return on investment (via energy efficiency) without risk to operational efficiency. During times of low energy costs, there is less incentive for companies to invest in energy efficiency technologies, and there are different drivers and barriers based on industry subsector. Considerations by Major Industry The following considerations have been identified where R&D could impact WHR in the specific major industries analyzed in this TA. 29 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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