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3 OPPORTUNITIES-BARRIERS-PATHWAYS FOR RECOVERY • • Apply catalytic separation/concentration technologies in chemical reaction and purification process in chemical, petroleum-refining, and pharmaceutical industries. Several physical separation techniques that avoid evaporation and freezing, such as membrane separation, have been developed that can improve efficiency. Potential energy savings from process flow optimization is estimated to be 2 EJ/year in the United States. Combustion is one way to capture energy of emissions from industrial processes. Improvements in combustion efficiency and use of advanced combustors are expected to save 30% in fuel. Potential energy savings from process optimization is estimated to be 2 EJ per year in the United States. Additional examples of energy savings in industrial processes are given below: • Industrial electric drives include pumps, compressors, conveyors, fans, machine tools – improvements in motors and other components are expected to save 33% of electricity consumed at present. • Electricity is consumed in reduction on alumina or aluminum chloride to aluminum. The Alcoa process consumes 30% less energy than the Hall-Heroult process. Energy savings from improved technology is expected to cut energy required by 33%. • In the iron and steel sector, electricity is mainly consumed by electric furnaces in the electric steel-making process. Furnace productivity can be increased by pre- heating the scrap, by operating at higher electric power levels, and by injecting oxygen. Energy consumption can be further reduced by direct rolling of continuously cast labs. These should save 25% of electricity by year end. • Petrochemical feedstock – Petrochemicals such as synthetic fibers, plastics, and fertilizers are produced using fossil feedstock. Energy can be saved by a more efficient use of materials. Potential Recovery Technologies for Thermal Emissions Conventional technologies exist and are under development that could enable more cost- effective recovery of thermal emissions from the industrial processes. The two most obvious technology classes for this technology are process heat exchange and thermal energy conversion devices. However, thermal emissions from the industrial complex vary in the temperature gradients available and distributed nature of the thermal emissions. This complexity will likely require that different technology approaches be employed to recover thermal emissions depending on the quality of heat available and the nature of the ancillary processes and the ability to redeploy heat within the processes. The most conventional method to re-use process heat is through heat exchangers. Heat exchangers permit the transfer of heat from one process fluid or gas to another. Heat exchangers can be used to transfer waste heat from process emissions to other locations that use it as process heat, thereby reducing overall energy demand. The ability to use 73PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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