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Figure 1. US Manufacturing Industry Energy Use, Breakdown by Fuel, 2002 Natural gas Electricity Coal Coke and breeze Residual fuel oil Distillate fuel oil and diesel fuel Liquified petroleum gas and natural gas liquids Other Total energy use: 16,273 trillion BTU. Data derived from (EIA 2002, Table 5.2) A recent study estimates that waste heat losses account for 13% to 18% of US industrial energy use (DOE 2003a). It is estimated 1.4 quadrillion BTU of waste heat could technically and economically be recovered by industry (Energetics and E3M 2004). If realized, this translates into US industrial energy savings of almost 9% at the current energy use level. Cost-Effective Waste-Heat Recovery and Reuse in Industry While the US manufacturing industry primarily uses electrical-powered machine drives, it relies heavily on fossil-fuel-fired process heating equipment and boilers. Indeed, natural gas accounts for about 70% of total energy used by process heating equipment in industry, followed by coal (10%) (EIA 2002). Natural gas also accounts for 70% of total energy used by industrial boilers, followed by coal (25%) (EIA 2002). Chemicals, paper, food processing, and petroleum refining industries dominate the use of fossil fuels for boiler operation, while the primary metals, chemicals, and petroleum refining industries dominate the use of fossil fuels for process heating equipment (EIA 2002). Process heating equipment and boilers release medium-to-high temperature exhaust gases, waste steam, and effluents. For example, exhausts gases from furnaces, kilns, incinerators and other process heating equipment are typically released at temperatures above 1,000 oF (Table 1). As a result, medium-to-high temperature exhaust gases from fossil-fuel-fired boilers and process heating equipment are prime candidates for waste-heat recovery. Cost-effective waste-heat recovery and reuse involves the identification of waste-heat sources of sufficient quality, quantity, and temporal availability, and heating loads that can reuse the waste heat recovered. There are numerous industrial processes available in the low-to- medium temperature range that can reuse waste heat, many of which are found in the food and beverage, textile, forest products, petrochemical, and chemicals industries (Table 1). For example, certain distillation operations in refineries and chemical plants are ideal for open-loop heat pump systems that mechanically recompress the “overhead” distillation vapor which is subsequently allowed to condense in the reboiler where it vaporizes the “bottoms” product in the distillation column. These applications typically involve small temperature differences and are often more cost-effective than using fuel combustion to heat the reboiler and a cooling tower to reject the heat in the distillate. . © 2007 ACEEE Summer Study on Energy Efficiency in Industry 2-3PDF Image | Industrial Waste Heat Recovery Benefits and Recent Advancements in Technology and Applications
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