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3 OPPORTUNITIES-BARRIERS-PATHWAYS FOR RECOVERY • • Industrial Materials Exchange Tool – developed by Bechtel and owned by Nexant– not available to others. Has been used in several industrial eco-systems project. EPA’s Designing Industrial Ecosystems Toolkit – helps users identify, screen, and optimize byproduct use opportunities at the regional scale. Chevron recently completed an energy-efficiency assessment for DOE-ITP for its refinery in Salt Lake City, Utah, and found that > 25000 million Btu’s could be saved annually by upgrading a debutanizer and completing a saturated gas plant project. Clearly, there are opportunities for energy capture using process integration. The purge gases from a catalytic cracking unit consist of various olefins. British Petroleum, as part of a DOE-OIT program, developed a hybrid membrane/distillation system to separate these olefins, resulting in estimated energy savings of 150 GBtu/year. In energy-intensive industries such as glass, oxygen-rich combustion can significantly reduce emissions and result in fuel savings, as determined by Praxair as part of a DOE- OIT program. In an industrial process, fuels are consumed in the form of heat for producing process steam, raising temperature, generating electricity to operate processes and machinery, and feed-stocks. Unless the electricity is generated within the plant, the emissions from this process cannot be recovered. But the emissions from process heat and feedstocks can be recovered. Halmann et al. [25] summarized the various energy savings resulting from process optimization. Ceramic heat recuperators will recover per year an estimated 2 exajoules (EJ) of thermal energy currently wasted with corrosive and potential fouling high-temperature exhaust streams. Metallic recuperators will recover an estimated 1.6- 3.2 EJ of process heat > 1000°F. New heat pump technology will upgrade an estimated 1-3 EJ of process heat from liquid and gas waste streams at 150-25-F, and bottoming- cycle engines for streams at < 700°F to a more useful temperature level. Development of organic working fluids will improve performance of organic Rankine cycle driven by low-temperature waste heat. Some examples of process optimization are given below: • Energy cascading – placement of processes that need lower quality energy so each uses waste heat from preceding process. • Combining process steam production with electricity generation in systems with high electrical to thermal output ratios – this applies only to cases where electricity generation is done within the plant. Data is still needed on which industries do this and how much electricity is generated within those industries in the plant. 72PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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