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IDC Energy Insights estimates that, based on the number of commercial boilers in the United States according to a May 2005 report published by the Oak Ridge National Laboratory titled, "Characterization of the U.S. Industrial/Commercial Boiler Population," another 300TBtu of work potential is available from this source. The 2008 DOE report estimates that heat losses from solid streams in the iron and steel industry total 600TBtu/year, which might translate into an additional 150TBtu of work potential. Work potential from cooling water is not included in the 1,050TBtu total work potential of waste heat estimated for the United States, but according to the 2008 DOE report, "large quantities of low-temperature waste heat are available in cooling water." Numerous additional sources of waste heat exist, but the above estimates include the sources that are most likely to be used for power generation. The sources are summarized in Table 1. Even within the sources covered, there is variability in the quality of the waste heat that impacts its suitability as a source for power generation. Three of the most important variables are temperature, flow rate, and cleanliness of the waste heat. Much of the existing heat recovery that is currently carried out in the United States (and which was excluded from the estimates of work potential above) utilizes "clean, high-temperature waste heat sources in large capacity systems," according to the 2008 DOE report. While some of the unrecovered high-temperature waste heat in the United States would be straightforward to capture and use with existing technologies, other sources are dirty and expensive to recover because the exhaust gas must be cleaned prior to use. Not only is the cleaning process expensive, but removing dirt from the hot-air stream removes heat at the same time, which then cannot be used for power generation. Other high-temperature waste heat is difficult to recover because of its basic nature, such as solid streams in the iron and steel industry. Over half of the unrecovered work potential from waste heat outlined in Table 1 is at low temperatures, under 450F (232C). The economic viability of these sources is tied directly to the cleanliness of the waste heat as well as its flow rate. Low-temperature waste heat sources with large flow rates can be economical to exploit with traditional organic Rankine cycle (ORC) technology because they enable large projects with significant electricity generation. Smaller projects at low temperatures are much more challenging to make economically viable, although a few companies are developing technologies to pursue this market. Page 2 #EI229456 ©2011 IDC Energy InsightsPDF Image | Waste Heat to Power Still Waiting for a Breakthrough
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