Waste heat recovery
48Pages

Waste heat recovery: technologically and economically viable solutions for industrial businesses A white book on industrial waste heat recovery Fives 2017

Preface Scarcity of resources and global warming are still two major issues for the early 21st century. To achieve sustainable development, the origin and the use of energy have to be addressed, and advanced energy technologies for both fossil and renewable energy carriers have to be developed, requiring significant progress in research and technology. Recent international crises leading to rising oil prices (even if in the last few years the relatively low cost has hidden this resource’s impending depletion) and major natural disasters that climate change could be driving, have made the...

About Fives Fives is an industrial engineering Group with a heritage of over 200 years of engineering excellence and expertise. Fives designs and supplies machines, process equipment and production lines for the world’s largest industrial groups in various sectors such as aluminium, steel, glass, automotive, logistics, aerospace, cement and energy, in both developing and developed countries. In all of these sectors, Fives designs and manufactures equipment and innovative solutions, which better anticipate and meet the needs of its customers in terms of performance, quality, safety and...

Lead author: Pauline Plisson, Innovation & Sustainability Program Manager, Fives Contributors: - Sebastien Devroe, Aurelie Gonzalez, Alienor Guiard, Guillaume Denis, Claire Mathieu (Fives) - Cement. Francois Boudot, Yannick Guimard (Fives FCB) - Aluminium: El-Hani Bouhabila, Adelaide Faux (Fives Solios) - Glass: Wolf Kuhn, Bertrand Strock (Fives Stein) - Steel: Patrick Giraud (Fives Stein) - CEA: Benjamin Boillot (Liten Institute) If you have any questions or want to get in touch with industry experts at Fives, please write to fives.innovation@fivesgroup.com Fives - A white...

Preface About Fives Authors & Contact Enhancing energy efficiency in industrial p.5 processes 1. Introduction 2. Waste heat recovery, the next challenge of energy-intensive industries 3. Energy conversion technologies Challenges & solutions by industrial sector p.14 Each focus per industrial sector provides insight into the context, the industry-specific challenges as well as the solutions that can be developed to recover waste heat. an investment in waste heat recovery Also, quantified case studies illustrate the potential gains. Fives - A white book on industrial waste heat recovery

Enhancing energy efficiency in industrial processes 5 Fives – A white book on industrial waste heat recovery

1. Introduction As global competition rises, developed countries strive to remain competitive, protect their industry and keep their manufacturing jobs. Some of these economies, such as Germany, France, the US and China, have launched programs to help their national industries achieve the transition that will ensure their long-term sustainability, competitiveness and attractiveness. However, the challenges of reinventing industry once more are substantial, both economically and socially, as well as in terms of environmental impacts. Industry is responsible for 32% of worldwide greenhouse...

2. Waste heat recovery, the next challenge of energy-intensive industries Given their share in the world’s greenhouse gas emissions, reduction of emissions from industries is critical to achieving the world’s commitment to fight climate change. Reducing the use of raw materials such as steel, aluminium and glass, whose production is highly energy- and CO2-intensive, is a viable option supported by recycling and circular economy programs but will not be sufficient. Another way to decrease CO2 emissions of processes that are energy intensive and intrinsically CO2 generators such as the cement...

Once a process has been made more efficient and its inputs have been substituted with low-impact sources, the next thing that can be improved is the process outputs, i.e. minimizing losses (Figure 1). In an industrial process, losses can be materials as well as wasted energy (Figure 2). Recovery and re-use of waste energy (which is most often heat) will be the focus of this white book. Special emphasis is given to re-using waste energy in another part of the plant or outside the plant. Re-use within the equipment (e.g. recirculation of a furnace’s flue gases inside the furnace) is already...

Approximately 4,000 TWh of heat are wasted every year in the world, which corresponds to emissions of 2,800 million metric tonnes of CO2 (source: US Department of Energy and ADEME). The European organization Energy Efficiency in Industrial Processes (EE-IP) has estimated that waste heat recovery has a CO2 emission reduction potential of 250 million tonnes/year in Europe 5. This corresponds to half of the emissions generated annually by the worldwide aluminium industry. Another challenge that manufacturers will need to address is flexibility. Today, as market conditions, customer...

3. Energy conversion technologies Recovery of wasted energy can be achieved using energy conversion technologies. These technologies can be classified depending on the type of energy input (thermal energy or waste heat, which will be the focus of this document, and other types such as pressure or motion), and on the type of energy output. Waste heat recovery technologies include: - Heat exchangers and heat storage solutions, which do not convert energy but simply transfer it to another medium or store it to make it available upon demand Heat pumps, which increase the temperature of a heat...

Output Technology Principle Fluid and temperature *uses a biphasic turbine capable of operating with low admission pressure (~2 bar) and weak flowrates Fives - A white book on industrial waste heat recovery

Conversion medium Heat source power and temperature As a general rule, it is possible to combine several modules to reach a higher power. The module size can be the maximum (power limit of the technology), or a standard size to lower the cost. The charts below give an approximate representation of the technologies' operating ranges (power and temperature). Fives - A white book on industrial waste heat recovery