heat recovery: the least sexy, most practical, clean energy source around
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heatcalc.com 1
Heatrecovery:theleastsexy,mostprac3cal,cleanenergysourcearound.
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heatcalc.com 2
Heat–bydefini5on–isaformofenergy
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heatcalc.com 3
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heatcalc.com 4
Andisavailableasabyproductofindustrialproduc5on
Usingheatasanenergysourceproduceszeroaddi5onalemissionsandoBenoffsetsfuel,electricity,orotherexpenses
CEMENT POWERGENSTEEL COMPRESSIONFOOD&BEV
REFININGCHEMICALSGLASS
Manyindustriescanbenefitfromheatu5liza5on
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heatcalc.com 5
Itjustdoesn’thavethecurbappealthatwind,solar,andothercleanenergytechnologiesdo.
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heatcalc.com 6
But,industrialheathasuniquelyaOrac5vequali5es
• Usingitproduceszeroemissions,requiresnofuel
• OBenavailable24x7,dayornight,regardlessoftheweather
• Candirectlyoffsetelectricityorfuelconsump5on
• Accessible,andmeasurable
• OBenavailableon-site,andusableon-siteornearby
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heatcalc.com 7
Itisalsoavailableinhugequan55esTotalenergylostasUS
industrialheat(5-13quadrillionBTU)
=Totalprimaryenergyconsump5onofItaly
(7quadrillionBTU)
20-50%ofUSIndustrialenergyislostasheat
Sources:USDOE;EnergyInforma5onAdministra5on
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Andit’saversa5lesourceofenergyBelowaretheprimary3op5onsforheatu5liza5on
Warmsomethingup• Spacehea5ng,drying,pre-hea5ng,etc.
Coolsomethingdown• Aircondi5oning,refrigera5on
Generateelectricity• Useon-site,orselltogrid
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heatcalc.com 9
HeatrecoveryhelpstheboOomline
Heatrecovery…“Improvesplantcompe33veposi3oninthemarket”
EBITDAmarginsatcementfactories
10-15%
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heatcalc.com 10
3componentsofawasteheatproject
• Furnaces• Ovens• Kilns• Incinerators• Turbines• Engines• Boilers• Excesssteam• Excesshotwater
• Forwarming:heatexchanger(s),steamorhotwaterloop
• Forcooling:absorp5onchiller• Forgenera3ngelectricity:ORC,thermoelectric,steamturbine,etc.
• OBenwithinsamesite• Hospitalhea5ng&cooling• Campushea5ng&cooling• Foodstoragerefrigera5on• Lumberdrying• Greenhousehea5ng• Combus5onairprehea5ng• Onsiteelectricity• Gridelectricity
2.Recoveryunit 3.User
Ideally,heatavailabilitymatchestheuser’sdemandschedule
1.Heatsource
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heatcalc.com 11
Example:heatforwarmingMul$plenaturalgasenginesgenerateelectricityforthegrid.Theengineheat–whichisanaturalbyproductofgenera$on–isusedinthedistricthea$nglooptowarmnearbybuildings.ThisarrangementiscalledCombinedheatandpower(CHP).
Benefits+ Operatorsreceiveprimaryenergysavings
of40%+ Avoidedtheaddi5onalcapexofboilersto
supplyhea5ng
www.dieselgasturbine.com
Districtenergyloop BuildingheatRecipengines
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heatcalc.com 12
Example:heatforcoolingAtanaluminumfacilityinDubai,aircondi$oningisrequiredformuchoftheyear.Absorp$onchillersconvertsmelterheatintoaircondi$oning,whichcoolstheworkerareasofthebuilding.Benefits+ Avoidedcapexonaircondi5oningunits+ Avoidedcostofelectricityfromrunning
theaircondi5oningunits+ Reducedelectricityconsump5onby
242GWh,enoughfor~23,000UShomes
hOp://en.energy-changes.com/
Absorp5onchillers BuildingACAluminumplant
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heatcalc.com 13
Example:heatforpowergenera5on
www.zkg.de
Heatatthiscementfacilityisextractedfrom3areas:therotarykiln,clinkercooler,andnitrogenoxideremovalplantandconvertedintoelectricitywithasinglesteamturbine.Benefits+ Offsets1/3oftheelectricityrequiredat
thesite+ CO2emissionsreducedby30,000tons/yr+ Energypricehedging
Steamturbine On-siteelectricityCementplant
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heatcalc.com 14
EachheatsourceisuniqueTypically,specsheetsormonitoringequipmentindicatethetemperature&flowrateoftheheatsource
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
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heatcalc.com 15
HeatCalc.commakessenseoftheheatdataByquan5fyingtheheatavailableatyoursource.Online.Free.
10,302kW
2,256kW
894kW
145kW
954kW
2,509kW
4,034kW
8,393kW
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heatcalc.com 16
HeatCalchastoolstohelpenableyourproject
HeatCalcquan3fiesyourheatsource• Calculatestheamountofheatavailableinyour
source,basedonyourspecificheatinputs• Providesideasforwhatyoucandowiththeheat• Connectsyouwiththerightsuppliersandenergy
servicecompaniestomakeyourprojectareality
Ahubofusefulheatrecoveryinforma3on• Exampleprojects/casestudies• Recentheatrecoverynews• Howto’sandrecommenda5ons
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visit us at heatcalc.com Enabling heat recovery projects worldwide