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TA 6M: Waste Heat Recovery 7 Lawrence Berkeley National Laboratory (LBNL) and American Council for an Energy-Efficient Economy (ACEEE), Emerging Energy-Efficient Industrial Technologies, October 2000. Available at: http://escholarship.org/uc/item/5jr2m969 8 McKinsey & Company, Unlocking Energy Efficiency in the U.S. Economy, July 2009. Available at: http://www.mckinsey.com/client_service/ electric_power_and_natural_gas/latest_thinking/unlocking_energy_efficiency_in_the_us_economy 9 U.S. DOE Office of Energy Efficiency & Renewable Energy, 2010 Manufacturing Energy and Carbon Footprints: Definitions and Assumptions. Available at: http://energy.gov/sites/prod/files/2014/02/f7/AMO_footprints_definitions_and_assumptions_2014_update.pdf. 10 U.S. DOE Office of Energy Efficiency & Renewable Energy, 2010 Manufacturing Energy and Carbon Footprints. Available at: http://energy.gov/ eere/amo/manufacturing-energy-and-carbon-footprints-2010-mecs. 11 U.S. DOE Office of Energy Efficiency & Renewable Energy, 2010 Manufacturing Energy and Carbon Footprint – All Manufacturing. Available at: http://energy.gov/sites/prod/files/2015/10/f27/manufacturing_energy_footprint-2010.pdf 12 Energetics Incorporated for Oak Ridge National Laboratory, U.S. Manufacturing Energy Use and Greenhouse Gas Emissions Analysis, prepared for the U.S. Department of Energy, Industrial Technologies Program, 2012. Available at: http://www.energy.gov/eere/amo/downloads/us- manufacturing-energy-use-and-greenhouse-gas-emissions-analysis. 13 Losses from process heating in the U.S. manufacturing sector total over 2.5 quads, as shown in the U.S. DOE Advanced Manufacturing Office (AMO) static Sankey diagram of process energy flows (http://www.energy.gov/eere/amo/static-sankey-diagram-process-energy-us- manufacturing-sector). Process heating losses in individual manufacturing subsectors can be explored using the AMO Dynamic Manufacturing Energy Sankey Tool (http://www.energy.gov/eere/amo/dynamic-manufacturing-energy-sankey-tool-2010-units-trillion-btu). All these loss numbers are first law of thermodynamics estimates of losses. 14 Pacific Northwest National Laboratory (PNNL) and BCS, Incorporated, Engineering Scoping Study of Thermoelectric Generator (TEG) Systems for Industrial Waste Heat Recovery, prepared for the U.S. Department of Energy, Industrial Technologies Program, November 2006. Available at: https://www1.eere.energy.gov/manufacturing/industries_technologies/imf/pdfs/teg_final_report_13.pdf 15 A thermoelectric material’s efficiency of converting heat to electricity is characterized by the dimensionless figure of merit ZT = (σS2T)/k where σ is the electrical conductivity, S is the Seebeck coefficient, T is the temperature, and k is the thermal conductivity. Thermoelectric materials with a ZT of ~1 are widely available. Advanced materials have now been demonstrated with a ZT of 2 and higher. 16 Oak Ridge National Laboratory (ORNL) and E3M Inc., Technologies and Materials for Recovering Waste Heat in Harsh Environments, Sachin Nimbalkar, Arvind Thekdi, et.al., ORNL/TM-2014/619. Available at: http://info.ornl.gov/sites/publications/files/Pub52939.pdf 17 U.S. DOE Advanced Manufacturing Office Dynamic Manufacturing Energy Sankey Tool, available at: http://www.energy.gov/eere/amo/ dynamic-manufacturing-energy-sankey-tool-2010-units-trillion-btu. Note that sources of waste heat losses include high temperature exhaust gases, in addition to hot surfaces, hot liquids, and hot products. The Recoverable Potential column in this table only examines the recoverable potential for WHR from high temperature exhaust gases. The process heating losses column shows the total process heating losses in each sector, irrespective of recovery potential. 18 Drew Robb, “Supercritical CO2 – The Next Big Step? Special Report, Turbomachinery International 53, No. 5, pp. 22-28, September/October 2012. 19 The barrier categories are described in the Waste Heat Recovery: Technology and Opportunities in U.S. Industry report as follows: • Long payback periods: Costs of heat recovery equipment, auxiliary systems, and design services lead to long payback periods in certain applications. • Material Constraints and Costs: Certain applications require advanced and more costly materials. These materials are required for high- temperature streams, streams with high chemical activity, and exhaust streams cooled below condensation temperatures. Overall material costs per energy unit recovered increase as larger surface areas are required for more efficient, lower temperature heat recovery systems • Maintenance Costs: Corrosion, scaling, and fouling of heat exchange materials lead to higher maintenance costs and lost productivity. • Economies of Scale: Equipment costs favor large-scale heat recovery systems and create challenges for small-scale operations • Lack of End-Use: Many industrial facilities do not have an on site use for low-temperature heat. In addition, technologies that create end use options (e.g., low temperature power generation) are currently less developed and more costly. • Heat Transfer Rates: Small temperature differences between the heat source and heat sink lead to reduced heat transfer rates and require larger surface areas. • Environmental concerns: WHR from exhaust streams may complicate or alter the performance of environmental control and abatement equipment. • Process Control and Product Quality: Chemically active exhaust streams may require additional efforts to prevent cross contamination between streams. • Process-Specific Constraints: Equipment designs are process specific and must be adapted to the needs of a given process. For example, feed preheat systems vary significantly between glass furnaces, blast furnaces, and cement kilns. • Inaccessibility: It is difficult to access and recover heat from unconventional sources such as hot solid product streams (e.g., ingots) and hot equipment surfaces (e.g., sidewalls of primary aluminum cells). 34 QuadrennialTechnologyReview2015PDF Image | Innovating Clean Energy Technologies in Advanced Manufacturing
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