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Heat Recovery: the least sexy, most practical, clean energy source around.


Published on | Heat energy is recoverable in huge amounts at industrial facilities across the world and represents an environmentally and economically attractive potential source of clean energy.

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Heat Recovery: the least sexy, most practical, clean energy source around.

  1. 1. 1 Heat recovery: the least sexy, most prac3cal, clean energy source around.
  2. 2. 2 Heat – by defini5on – is a form of energy
  3. 3. 3
  4. 4. 4 And is available as a byproduct of industrial produc5on Using heat as an energy source produces zero addi5onal emissions and oBen offsets fuel, electricity, or other expenses CEMENT POWER GEN STEEL COMPRESSION FOOD & BEV REFINING CHEMICALS GLASS Many industries can benefit from heat u5liza5on
  5. 5. 5 It just doesn’t have the curb appeal that wind, solar, and other clean energy technologies do.
  6. 6. 6 But, industrial heat has uniquely aOrac5ve quali5es •  Using it produces zero emissions, requires no fuel •  OBen available 24x7, day or night, regardless of the weather •  Can directly offset electricity or fuel consump5on •  Accessible, and measurable •  OBen available on-site, and usable on-site or nearby
  7. 7. 7 It is also available in huge quan55es Total energy lost as US industrial heat (5-13 quadrillion BTU) = Total primary energy consump5on of Italy (7 quadrillion BTU) 20-50% of US Industrial energy is lost as heat Sources: US DOE; Energy Informa5on Administra5on
  8. 8. And it’s a versa5le source of energy Below are the primary 3 op5ons for heat u5liza5on Warm something up •  Space hea5ng, drying, pre-hea5ng, etc. Cool something down •  Air condi5oning, refrigera5on Generate electricity •  Use on-site, or sell to grid
  9. 9. 9 Heat recovery helps the boOom line Heat recovery… “Improves plant compe33ve posi3on in the market” EBITDA margins at cement factories 10-15%
  10. 10. 10 3 components of a waste heat project •  Furnaces •  Ovens •  Kilns •  Incinerators •  Turbines •  Engines •  Boilers •  Excess steam •  Excess hot water •  For warming: heat exchanger(s), steam or hot water loop •  For cooling: absorp5on chiller •  For genera3ng electricity: ORC, thermoelectric, steam turbine, etc. •  OBen within same site •  Hospital hea5ng & cooling •  Campus hea5ng & cooling •  Food storage refrigera5on •  Lumber drying •  Greenhouse hea5ng •  Combus5on air prehea5ng •  On site electricity •  Grid electricity 2. Recovery unit 3. User Ideally, heat availability matches the user’s demand schedule 1. Heat source
  11. 11. 11 Example: heat for warming Mul$ple natural gas engines generate electricity for the grid. The engine heat – which is a natural byproduct of genera$on – is used in the district hea$ng loop to warm nearby buildings. This arrangement is called Combined heat and power (CHP). Benefits +  Operators receive primary energy savings of 40% +  Avoided the addi5onal capex of boilers to supply hea5ng District energy loop Building heat Recip engines
  12. 12. 12 Example: heat for cooling At an aluminum facility in Dubai, air condi$oning is required for much of the year. Absorp$on chillers convert smelter heat into air condi$oning, which cools the worker areas of the building. Benefits +  Avoided capex on air condi5oning units +  Avoided cost of electricity from running the air condi5oning units +  Reduced electricity consump5on by 242GWh, enough for ~23,000 US homes hOp:// Absorp5on chillers Building AC Aluminum plant
  13. 13. 13 Example: heat for power genera5on Heat at this cement facility is extracted from 3 areas: the rotary kiln, clinker cooler, and nitrogen oxide removal plant and converted into electricity with a single steam turbine. Benefits +  Offsets 1/3 of the electricity required at the site +  CO2 emissions reduced by 30,000 tons / yr +  Energy price hedging Steam turbine On-site electricity Cement plant
  14. 14. 14 Each heat source is unique Typically, spec sheets or monitoring equipment indicate the temperature & flow rate of the heat source 252°C @ 200m3/min 856°F @ 245c3/hr 512°F @ 502c3/s 192°C @15m3/s 352°C @ 800kg/min 459°C @ 8kg/s 946°F @ 24lbs/s 490°C @ 24kg/s
  15. 15. 15 makes sense of the heat data By quan5fying the heat available at your source. Online. Free. 10,302 kW 2,256 kW 894 kW 145 kW 954 kW 2,509 kW 4,034 kW 8,393 kW
  16. 16. 16 HeatCalc has tools to help enable your project HeatCalc quan3fies your heat source •  Calculates the amount of heat available in your source, based on your specific heat inputs •  Provides ideas for what you can do with the heat •  Connects you with the right suppliers and energy service companies to make your project a reality A hub of useful heat recovery informa3on •  Example projects / case studies •  Recent heat recovery news •  How to’s and recommenda5ons
  17. 17. visit us at Enabling heat recovery projects worldwide