The document discusses heat recovery in industry. It notes that heat recovery can provide thermal energy for internal or external heating demands, or can be upgraded for uses like cooling or electricity generation. Effective heat recovery requires considering factors like the temperature and availability of waste heat sources, the technologies available, investment criteria, characteristics of potential heat users, and the location of heat sources and users. Heat recovery can support district heating for industries, buildings, and other sectors.
2. 2
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4. 4
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6. Consumi finali in Italia
6
!35,0%'
!30,0%'
!25,0%'
!20,0%'
!15,0%'
!10,0%'
!5,0%'
0,0%'
5,0%'
10,0%'
2005' 2006' 2007' 2008' 2009' 2010' 2011' 2012' 2013'
Variazione)consumi)finali)rispe1o)al)2005)
INDUSTRIA' TRASPORTI' CIVILE'
Fonte:'elaborazioni'FIRE'su'daK'MiSE'
La crisi ha colpito il
settore industriale.
Il settore trasporti ha
subito anche l’effetto
del caro petrolio
nell’ultimo triennio.
Il settore civile ha
operato in tendenziale
controtendenza.
7. Consumi finali nell’industria
70,000#
2,000#
4,000#
6,000#
8,000#
10,000#
12,000#
14,000#
16,000#
18,000#
2005# 2006# 2007# 2008# 2009# 2010# 2011# 2012# 2013#
Mtep%
%
Consumi%industriali%per%fonte%energe3ca%
%
Gas#naturale#
Energia#ele9rica#
Petrolio#
Carbone#
Rinnovabili#
Fonte:#elaborazioni#FIRE#su#daF#MiSE#
41,061& 40,896&
39,567&
37,412&
29,955&
32,146&
32,656&
30,190&
28,175&
25&
27&
29&
31&
33&
35&
37&
39&
41&
43&
2005& 2006& 2007& 2008& 2009& 2010& 2011& 2012& 2013&
Mtep&
Consumi&finali&di&energia&in&fon?&primarie&nel&se@ore&industriale&
&
Fonte:'elaborazioni'FIRE'su'da4'MiSE'
L’industria vede un
andamento simile dei
consumi di gas naturale
ed elettricità, mentre
petrolio e rinnovabili
evidenziano un calo
sostenuto.
La domanda che sorge
spontanea è: quanto di
questa riduzione dei
consumi è imputabile
all’efficienza energetica?
13. Considerazioni sui recuperi termici
Fonte: “Waste heat recovery: technology and opportunities in U.S. industry”, rapporto DOE, 2008
13
Table 4 Temperature Classification of Waste Heat Sources and Related Recovery Opportunity
Temp Range Example Sources Temp (°F) Temp (°C) Advantages
Disadvantages/
Barriers
Typical Recovery Methods/
Technologies
Nickel refining furnace 2,5003,000 1,3701,650 Highquality energy, High temperature creates Combustion air preheat
Steel electric arc furnace 2,5003,000 1,3701,650 available for a diverse increased thermal
Basic oxygen furnace 2,200 1,200
range of enduses with
varying temperature
stresses on heat
exchange materials
Steam generation for process
heating or for mechanical/
Aluminum reverberatory
furnace
2,0002,200 1,1001,200 requirements
Increased chemical
electrical work
High
Copper refining furnace 1,4001,500 760820 Highefficiency power activity/corrosion Furnace load preheating
>1,200°F Steel heating furnace 1,7001,900 9301,040 generation
[> 650°C] Copper reverberatory furnace 1,6502,000 9001,090 Transfer to medlow
Hydrogen plants 1,2001,800 650980 High heat transfer rate per
unit area
temperature processes
Fume incinerators 1,2002,600 6501,430
Glass melting furnace 2,4002,800 1,3001,540
Coke oven 1,2001,800 6501,000
Iron cupola 1,5001,800 820980
Steam boiler exhaust 450900 230480 More compatible with Combustion air preheat
Gas turbine exhaust 7001,000 370540 heat exchanger Steam/ power generation
Medium Reciprocating engine exhaust 6001,100 320590
materials Organic Rankine cycle for
4501,200°F
[230650°C]
Heat treating furnace
Drying & baking ovens
8001,200
4501,100
430650
230590
Practical for power
generation
power generation
Furnace load preheating,
feedwater preheating
Cement kiln 8401,150 450620 Transfer to lowtemperature
processes
Exhaust gases exiting recovery
devices in gasfired boilers,
ethylene furnaces, etc.
150450 70230 Large quantities of low
temperature heat
contained in numerous
Few end uses for low
temperature heat
Space heating
Domestic water heating
Process steam condensate
Cooling water from:
130190 5090 product streams. Lowefficiency power
generation Upgrading via a heat pump to
furnace doors 90130 3050 increase temp for end use
Low annealing furnaces 150450 70230 For combustion exhausts,
<450°F air compressors 80120 3050
lowtemperature heat Organic Rankine cycle
[<230°C] internal combustion
engines
150250 70120
recovery is impractical
due to acidic
condensation and heat
air conditioning and
refrigeration condensers
90110 3040 exchanger corrosion
Drying, baking, and curing
ovens
200450 90230
Hot processed liquids/solids 90450 30230
14. Considerazioni sui recuperi termici
Fonte: “Waste heat recovery: technology and opportunities in U.S. industry”, rapporto DOE, 2008
14
Table A – Research, Development, and Demonstration Needs for Addressing -
Waste Heat Recovery Barriers -
RD&D Opportunity Barriers Addressed
LongPayback
Periods
Material
ConstraintsandCosts
Maintenance
Costs
Economiesof
Scale
LackofEnduse
HeatTransferRates
EnvironmentalConcerns
ProcessControl
andProductQuality
Processspecific
Constraints
Inaccessibility
Develop lowcost, novel materials for resistance to
corrosive contaminants and to high temperatures
x x
Economically scaledown heat recovery equipment (value
engineer)
x x x
Develop economic heat recovery systems that can be
easily cleaned after exposure to chemically active gases x x x
Develop novel manufacturing processes that avoid
introducing contaminants into offgases in energyintensive
manufacturing processes
x x x x x
Develop lowcost dry gas cleaning systems x x x x x
Develop and demonstrate lowtemperature heat recovery
technologies, including heat pumps and lowtemperature
electricity generation.
x x
Develop alternative enduses for waste heat x
Develop novel heat exchanger designs with increased heat
transfer coefficients
x x x
Develop processspecific heat recovery technologies x x x x x x
Reduce the technical challenges and costs of process
specific feed preheating systems
x x x x x
Evaluate and develop opportunities for recovery from
unconventional waste heat sources (e.g., sidewall losses)
x x
Promote new heat recovery technologies such as solid
state generation x x
Promote lowcost manufacturing techniques for the
technologies described above
x x x x x x x x x x
15. Heat recovery nel Regno Unito
Fonte: “The potential for recovering and using surplus heat from industry”, rapporto Ecofys per DECC, 2014.
15
The total energy in waste heat sources in the database is identified as 48 TWh/yr and 20
TWh/yr in sinks. These databases contain 73 sites, for which in total 467 sources and
1091 sinks are included.
What is immediately apparent is the higher absolute level of heat sources than sinks within
the largest industrial emitters. This suggests that the available demand for low grade heat
is likely one of the key limiting factors for the reuse of heat, i.e. local demand is likely to be
quickly saturated. This would require external sink options such as heat networks and heat
to power conversion. This is also consistent with the experience of industrial players, who
often indicated in site visits that although waste heat is available, there is limited low grade
heat demand.
To understand the supply of waste heat and the characteristics of sinks, Figure 4
differentiates heat sources and heat sinks into differentiated temperature bands and the
medium in which heat is available (sources) or required (sinks). The waste heat source
bands are ambient-250°C (low),250-500°C (med), and >500 °C (high). The heat sink
bands are ambient-150°C (low), 150-250°C (med), and >250 °C (high).
Sources in database (TWh/yr) Sinks in database (TWh/yr) 26
If there is the potential for on-site re-use of heat, then this is usually more favourable in
terms of CO2 abatement potential. The estimation of the technical potential is based on
maximising system abated CO2. Heat delivery over-the-fence generally has a lower
specific abatement potential than on site re-use, due to heat losses in transport and power
requirements for pumping. The specific abatement potential of heat to electricity
technologies is significantly lower still, due to the low heat to electricity efficiency at the low
temperatures of rejected heat.
Figure 7 Application type of recovered heat in the technical potential, for different
technology categories and on-site, over-the-fence and electricity-production
applications. Base case. Data have been rounded where necessary.
The dominant technologies for heat recovery are heat exchangers, with heat pumps and
heat to electricity technologies providing a significant lower contribution to the technical
potential.
16. Heat recovery nel Regno Unito
Fonte: “The potential for recovering and using surplus heat from industry”, rapporto Ecofys per DECC, 2014.
16
abatement, being 8 TWh/yr and 1.9 Mt/yr, respectively. The potential of economically
recoverable heat, under private investor assumptions (10% discount rate), is
approximately 7 TWh
15
which corresponds to 1.6Mt of CO2 abatement per year. The
commercial potential takes into account only those source-sink-technology combinations
with a payback time less than two years. This results in 5 TWh/yr source heat utilised and
1.1 Mt CO2 abated/yr.
The main reduction of the recoverable heat potential going from the technical to the private
economic potential are the heat to power and heat pump projects. These are technically
feasible but are not economic under the private base case assumptions.
The economic potential is primarily made up of heat re-use options on site, as shown in
Figure 12.
The main bottleneck that reduces the economic attractiveness of over-the-fence heat
delivery are the costs for the heat transport infrastructure. While the technical potential
includes also a significant number of over-the-fence heat delivery options and heat to
electricity conversion, these are mostly not economically viable under the base case
private assumptions. Taking into account only the commercial potential of projects with a
15
To put these figures into context, the economic potential of 7 TWh reflects 2.4% of
overall UK industrial heat energy use (ca. 291 TWh/yr) and ca. 4% of heat energy use
within the leading eight heat intensive sectors (164 TWh/yr excl. power).
Figure 11 The economic potential for recoverable heat in UK industry, displayed
for the social, private and commercial base case.
WACC 3,5%
WACC 10%
PBT < 2%
The potential for recovering
and using surplus heat from industry
Final Report
payback time of less than two years, the relative contribution of over-the-fence heat
delivery reduces even further.
Figure 12 Application type of recovered heat in the technical, economic and
commercial potential. Private base case.
17. Heat recovery nel Regno Unito
Fonte: “The potential for recovering and using surplus heat from industry”, rapporto Ecofys per DECC, 2014.
17
The potential for recoverin
and using surplus heat from indust
Final Repo
5.3 Sensitivity analysis of UK economic potential
By varying exogenous parameters, we found that the economic potential for heat recove
is most sensitive to the commercial requirement of maximum two year payback, fu
prices, capex changes and the amount of waste heat available from industry.
The total net benefit is strongest impacted by fuel prices, applying the non traded sect
CO2 prices and social investment criteria. The latter two parameters have a significa
impact on the revenue, as expressed in Figure 19, but not sufficiently to turn the busines
case of many options negative, under the private economic scenario assumptions.
Figure 18 Impact of high and low sensitivities on the economic potential for he
17
and Climate Change (DECC) committed to assessing the potential for recovery and re-use
of industrial waste heat to contribute to meeting the UK’s energy challenges and legally
binding CO2 reduction target.
The potential for heat recovery is governed by multiple factors. These include the
characteristics of waste heat source(s) and heat sink(s), the compatibility of sources and
sinks (i.e. temperatures, capacity, timing, location), the available heat recovery
technologies (costs and efficiency), energy/carbon prices, investor priorities and site- or
ndustry-specific issues. To understand these drivers, databases of industrial waste heat
sources, heat sinks and heat recovery technologies have been constructed based on
iterature data and updated following discussions with industry.
A novel techno-economic model framework identifies a potential for industrial heat
recovery in the UK in the range of 5TWh/yr to 28TWh/yr, consisting of hundreds of source-
sink-technology combinations. The lower range of this estimate consists of measures that
already comply with commercial payback requirements, while the higher end of this range
would require significant development of heat networks and district heating, in order to be
realised.
The analysis identifies a technical potential of 11 TWh/yr from heat sources, based on
projects that are projected to save 2.2 MtCO2/yr. The technical potential includes
contributions from on-site heat re-use, over-the-fence supply to another large industrial
user and conversion to power. All heat-intensive industrial sectors examined (refineries,
ron & steel, ceramics, glass, cement, chemicals, food and drink, paper and pulp)
contribute to this potential. The technical potential is sensitive to industrial heat demand
and supply, and CO savings are also sensitive to assumptions on avoided fuel use.
19. Efficienza: un intervento, molti benefici
Source: IEA, Capturing the multiple benefits of energy efficiency. 1919
Vale anche per i
recuperi termici. Che
impatto hanno sulla
value proposition e
sul core business?
21. 21
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