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Figure 5 Energy consumption of industries Worldwide in 2010 [7] The energy consumption within a type of industry depends strongly on the number and size of companies or manufacturing sites respectively. This also means that the statistic looks different for each country. Nevertheless it has been possible to identify energy-consuming industries appearing in various countries, resulting in a ranking of industrial processes to be focused at. For this project the following industries are defined as energy-intensive and are worth analyzing for their waste heat potential: Classification according to ISIC [1] Division 24 Division 23 Division 19 Division 10 Division 17 Division 25 Section D Section E Description of the industry Manufacture of basic metals Manufacture of other non-metallic mineral products Manufacture of chemicals and chemical products Manufacture of food products Manufacture of paper and paper products Manufacture of fabricated metal products, except machinery and equipment Electricity, gas, steam and air conditioning supply Water supply; sewerage, waste management and remediation activities Table 1 List of energy-intensive industries 3.3. Investigation of the industries to their possible waste heat potential for ORC systems Cement industry: Cement production is one of the most energy intensive processes, the main chemical reaction theoretically requiring energy of 1’700 MJ to produce 1 ton of clinker material. In reality the energy requirements increases to about 3’000 to 6’000 MJ/t cli, depending on the technology in use. Such a difference between the theoretical and the practical energy consumption opens the door to a huge potential in energy savings. Figure 6 Left: Diagram of a standard 4-stage preheater cement kiln system; right: Heat balance of a dry kiln (3200 kJ/kg cli) Modern cement plants kiln systems have efficiency between 50-60%. Most of the energy losses are in the form of sensible heat in high temperature exhausts gases out of the preheater and hot air out of the cooler with about 34 %PDF Image | Application of Organic Rankine Cycles (ORC)
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