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1. Introduction
Waste heat energy and waste pressure energy are two main sources of waste
energy in current industry scenario. In this paper these terms are used synonymously as in
most cases waste energy includes both heat and pressure energies. Waste energy refers to the
energy generated in any industrial process but is released into environment without utilizing
it to full value. Common forms in which waste heat and pressure energy is available are hot
exhaust gases, used up steam, compressed air and hot water. In any industry economic
analysis and efficiency calculations related to production of waste energy are very important.
It aids in figuring out the energy losses and identifying the control measures that can be
applied. Various sources producing waste heat and pressure energy are reviewed in this
paper.
Waste heat is heat, which is generated in a process by way of fuel combustion
or chemical reaction, and then “dumped” into the environment even though it could still be
reused for some useful and economic purpose. The essential quality of heat is not the
amount but rather its “value”. The strategy of how to recover this heat depends in part on the
temperature of the waste heat gases and the economics involved. Large quantity of hot flue
gases is generated from Boilers, Kilns, Ovens and Furnaces. If some of this waste heat could
be recovered, a considerable amount of primary fuel could be saved. The energy lost in
waste gases cannot be fully recovered. However, much of the heat could be recovered and
loss minimized by adopting following measures as outlined in this chapter.
1.1 Defination of Waste Heat
Waste heat is the energy associated with waste streams of air, exhaust gases, and/or
liquids that leave the boundaries of an industrial facility and enter the environment. In the
definition of waste heat, it is implicit that the waste streams eventually mix with atmospheric
air or groundwater and that the energy contained within them becomes unavailable as useful
energy.
The absorption of waste energy by the environment is often termed thermal pollution. In
a more restricted definition, waste heat is the energy that is rejected from a process at a
temperature high enough to permit the recovery of some fraction of the energy for useful
purposes in an economic manner. Usually the energy being transferred is the sensible energy
(or internal thermal energy) of the fluid, but it can also include the transfer of the latent

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energy of the fluid. Latent heat exchange is typically associated with a phase change
between the vapor and liquid states of the fluid, such as condensation and boiling. For
example, the recovery of waste heat from hot and moist air used in the lumber drying
process involves the recovery of both sensible and latent.
1.2 Need for this Study
The purpose of this report is to identify RD&D efforts required to expand waste heat
recovery practices across the industrial sector. Numerous sources indicate a significant
percentage (20-50%) of industrial energy inputs is lost as waste heat. However, there is a
lack of information on the source of the largest waste heat losses in different sectors and
processes and the nature of different waste heat sources (e.g., the waste heat quality and
chemical composition) knowledge of these factors is critical in determining the feasibility
and extent of opportunity for waste heat recovery. This study identifies Research
Development & Demonstration (RD&D) needs built on a detailed investigation of waste
heat losses and barriers across various energy intensive processes or equipment.
This study uses approach to identify technology needs in industrial waste heat
recovery by characterizing specific, large industrial waste heat streams, describing current
recovery practices and barriers, and using these results to identify Research Development &
Demonstration (RD&D) needs. The report evaluates unrecovered waste heat from some of
the most energy intensive processes in manufacturing. The investigation focuses primarily
on exhaust streams from high temperature processes since these applications are some of the
most significant sources of high quality waste heat. However, during the course of this study,
it also became apparent that nonconventional sources of waste heat such as losses from
heated products, and lower quality waste heat should also be targeted for research in heat
recovery technologies.

2. LITERATURE SURVEY

Upendra S Gupta[1], focuses on the need of better and newer energy recovery methods
and to increase the efficiency of systems by harnessing maximum energy from waste
sources, According to his research estimates about 20 to 50% of total energy input is lost in
the form of exhaust gases. The paper highlightes the effectiveness of a counter flow vortex
tube applied to recover waste energy.

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Cecilia Arzbaecher[2], states the benefits and recent advancements in technology .The
Paper confirms that systematic waste heat recovery projects based on thermodynamic
Principles can yield annual energy cost saving of 10 % to 20% with paybacks of 6 to 18
months for industrial facilities.

CHP (Combined Heat & Power Partnership)[3], states the process of capturing heat given
out by an existing industrial process and using the heat to generate power. The paper
explains the working of ‘Steam Rankine Cycle’ for power generation. The paper also
explains a number of flared energy sources in petroleum, chemical, Oil & gas production
that can utilize the WHP i.e the Waste Heat to Power process.

3. Factors Affecting Waste Heat Recovery

Evaluating the feasibility of waste heat recovery requires characterizing the waste heat
source and the stream to which the heat will be transferred. Important waste stream
parameters that must be determined include:

A) Heat quantity
B) Heat temperature/quality

These parameters allow for analysis of the quality and quantity of the stream and also
provide insight into possible materials/design limitations. For example, corrosion of heat
transfer media is of considerable concern in waste heat recovery, even when the quality and
quantity of the stream is acceptable.

A) Heat Quality
Depending upon the type of process, waste heat can be rejected at virtually any
temperature from that of chilled cooling water to high temperature waste gases from an
industrial furnace or kiln. Usually higher the temperature, higher the quality and more cost
effective is the heat recovery. In any study of waste heat recovery, it is absolutely necessary
that there should be some use for the recovered heat. Typical examples of use would be
preheating of combustion air, space heating, or pre-heating boiler feed water or process
water. With high temperature heat recovery, a cascade system of waste heat recovery may be
practiced to ensure that the maximum amount of heat is recovered at the highest potential.

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An example of this technique of waste heat recovery would be where the high temperature
stage was used for air pre-heating and the low temperature stage used for process feed water
heating or steam raising.
B) Heat Quantity

The quantity, or heat content, is a measure of how much energy is contained in a

waste heat stream, while quality is a measure of the usefulness of the waste heat. The
quantity of waste heat contained in a waste stream is a function of both the temperature and
the mass flow rate of the stream:
E = mh(t)
Where ‘E’ is the waste heat loss;
‘m’ is the waste stream mass flow rate;
‘h(t)’ is the waste stream specific enthalpy,as a function of temperature.
Enthalpy is not an absolute term, but must be measured against a reference state (for
example, the enthalpy of a substance at room temperature and atmospheric pressure). In this
report, the enthalpy of waste heat streams is calculated at atmospheric pressure and two
reference temperatures: 77°F [25°C] and 300°F [150°C]. A reference of 77°F [25ºC] was
used to provide a basis for estimating the maximum heat attainable if a gas is cooled to
ambient temperature. The second reference temperature of 300°F [150ºC] is more
representative of current industrial practices since the majority of industrial heat recovery
systems do not cool gases below this value.
Factors Affecting Recovery Feasibility

A) Heat Quantity
The net heat content of a stream is termed as its heat quantity while quality is a
measure of the usefulness of the waste heat. Heat quantity depends upon the mass flow rate,
heat capacity and the temperature of the fluid.
E` = m`CT
Where E`= waste heat loss per unit time
m`= mass flow rate of fluid stream
C= specific heat of fluid
T= temperature of stream

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It must be noted that enthalpy is not an absolute term, but must be measured against a
reference state [1].

B) Temperature
Temperature of the source determines its quality and the method to be applied. It
defines the physical state of stream establishing its effectiveness as a waste energy source.
For example superheated steam is a better quality source than wet steam for same pressure.
C) Pressure
Pressure of the working fluid is of prime importance. High pressure sources provide
more energy but usually require costlier recovery setups. Pressure is the key factor for
determining the efficiency of recovery in processes like piezoelectricity generation and
vortex tube application.
4. Development of a Waste Heat Recovery System:
4.1 Understanding the process:

Understanding the process is essential for development of Waste Heat Recovery

system. This can be accomplished by reviewing the process flow sheets, layout diagrams,
piping isometrics, electrical and instrumentation cable ducting etc. Detail review of these
documents will help in identifying:
a) Sources and uses of waste heat
b) Upset conditions occurring in the plant due to heat recovery
c) Availability of space
d) Any other constraint, such as dew point occurring in an equipments etc.
After identifying source of waste heat and the possible use of it, the next step is to select
suitable heat recovery system and equipments to recover and utilise the same.
4.2 Benefits of Waste Heat Recovery:

Reduction in pollution
A number of toxic combustible wastes such as carbon monoxide gas, sour gas,
carbon black off gases, oil sludge, Acrylonitrile and other plastic chemicals etc, releasing to
atmosphere if/when burnt in the incinerators serves dual purpose i.e. recovers heat and
reduces the environmental pollution levels[2].

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Reduction in equipment sizes

Waste heat recovery reduces the fuel consumption, which leads to reduction in the
flue gas produced. This results in reduction in equipment sizes of all flue gas handling
equipments such as fans, stacks, ducts, burners, etc[2].
Reduction in auxiliary energy consumption
Reduction in equipment sizes give additional benefits in the form of reduction in
auxiliary energy consumption like electricity for fans, pumps etc.
Reduces energy costs
All recovered waste heat directly replaces purchased energy, thereby reducing
energy costs.
Reduces cost of capital equipment
Reuse of waste heat allows for the use of smaller energy conversion equipment
capacity, often resulting in savings in capital expenditures offsetting the cost of the heat
recovery system.
Reduces operating costs
Since waste heat recovery reduces energy costs and often also reduces capital costs,
it reduces operating costs.
Reduces environmental impact
Because all waste-heat recovery directly replaces purchased energy, it also reduces
the environmental impact on air and water.
Reduces GHG emissions
Waste-heat recovery by industry reduces GHG emissions associated with industrial
operation.

4.3 Sources

In the majority of energy applications, energy is required in multiple forms. These

energy forms typically include some combination of: heating, ventilation, and air
conditioning mechanical energy and electric power. Often, these additional forms of energy
are produced by a heat engine, running on a source of high-temperature heat. A heat engine

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can never have perfect efficiency, according to the second law of thermodynamics, therefore
a heat engine will always produce a surplus of low-temperature heat. This is commonly
referred to as waste heat or "secondary heat", or "low-grade heat". This heat is useful for the
majority of heating applications, however, it is sometimes not practical to transport heat
energy over long distances, unlike electricity or fuel energy.
5. Heat recovery devices / systems

Waste heat found in the exhaust gas of various processes or even from the exhaust
stream of a conditioning unit can be used to preheat the incoming gas. This is one of the
basic methods for recovery of waste heat. Many steel making plants use this process as an
economic method to increase the production of the plant with lower fuel demand.
There are many different commercial recovery units for the transferring of energy from hot
medium space to lower one:
5.1 Recuperators:

A recuperator is a special purpose counter-flow energy recovery heat exchanger

positioned within the supply and exhaust air streams of an air handling system, or in the
exhaust gases of an industrial process, in order to recover the waste heat . This name is given
to different types of heat exchanger that the exhaust gases are passed through, consisting of
metal tubes that carry the inlet gas and thus preheating the gas before entering the process.
The heat wheel is an example which operates on the same principle as a solar air
conditioning unit

Fig 1.Recuperators

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5.2 Regenerators:

This is an industrial unit that reuses the same stream after processing. In this type of
heat recovery, the heat is regenerated and reused in the process.

Fig:2 Regenarators

5.3 Heat pipe exchanger:

A heat pipe can transfer up to 100 times more thermal energy than copper, the best-
known conductor. In other words, heat pipe is a thermal energy absorbing and transferring
system that has no moving parts and hence require minimum maintenance.

The heat pipe comprises of three elements: a sealed container, a capillary wick
structure and a working fluid. The capillary wick structure is integrally fabricated into the
interior surface of the container tube and sealed under vacuum.

Thermal energy applied to the external surface of the heat pipe is in equilibrium with
its own vapour as the container tube is sealed under vacuum. Thermal energy applied to the
external surface of the heat pipe causes the working fluid near the surface to evaporate

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instantaneously. The vapour absorbs the latent heat of vaporization and this part of the heat
pipe becomes an evaporator region. The vapour then travels to the other end the pipe where
the thermal energy is removed causing the vapour to condense into liquid again, thereby
giving up the latent heat of the condensation. This part of the heat pipe works as the
condenser region. The condensed liquid then flows back to the evaporated region.

Fig: 3 Heat Exchanger Pipe

5.4 Economizer:
In case of process boilers, waste heat in the exhaust gas is passed along a recuperator
that carries the inlet fluid for the boiler and thus decreases thermal energy intake of the inlet
fluid.
As shown in the fig 4 water to be pre heated to be fed to the inlet of a boiler is passed
into the inlet coils of the economizer , flue gases (exhaust) having high temperature are then
passed over the coils by which the heat transfer takes places resulting in high temperature
water at the outlet .

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Fig4.Economiser

5.5 Heat pumps:

Using an organic fluid that boils at a low temperature means that energy could be
regenerated from waste fluids. Fig 5 shows a heat pump is a device that
provides heatenergy from a source of heat to a destination called a "heat sink". Heat
pumps are designed to move thermal energy opposite to the direction of
spontaneous heat flow by absorbing heat from a cold space and thereby releasing it to a
warmer one. Heat pumps use a refrigerant as an intermediate fluid to absorb heat where it
vaporizes, in the evaporator, and then to release heat where the refrigerant condenses, in the
condenser.

Fig:5. Heat Pumps

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6. WASTE SOURCE AND QUALITY

In considering the potential for heat recovery, it is useful to note all the possibilities,

and grade the waste heat in terms of potential value as shown in the following Table 1

TABLE 1 :WASTE SOURCE AND QUALITY

SR.NO SOURCE QUALITY

1 Heat in flue gases. The higher the temperature, the

greater the potential value for heat
recovery

2 Heat in vapour streams. As above but when condensed,

latent heat also recoverable.

3 Convective and radiant heat lost Low grade – if collected may be

from exterior of equipment used for space heating or air
preheats.

4 Heat losses in cooling water. Low grade – useful gains if heat is

exchanged with incoming fresh
water.

5 Heat losses in providing chilled a) High grade if it can be utilized to

water or in the disposal of reduce demand for refrigeration.
chilled water.
b) Low grade if refrigeration unit
used as a form of heat pump.

6 Heat stored in products leaving Quality depends upon temperature.

the process

7. Waste Heat to Power

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Waste heat to power (WHP) is the process of capturing heat discarded by an existing
industrial process and using that heat to generate power Fig 6.[3]. Energy intensive
industrial processes—such as those occurring at refineries, steel mills, glass furnaces, and
cement kilns—all release hot exhaust gases and waste streams that can be harnessed with
well established technologies to generate electricity[3]. The recovery of industrial waste heat
for power is a largely untapped type of combined heat and power (CHP), which is the use of
a single fuel source to generate both thermal energy (heating or cooling) and electricity.

CHP generally consists of a prime mover, a generator, a heat recovery system and
electrical interconnection equipment configured into an integrated system. CHP is a form of
distributed generation, which, unlike central station generation, is located at or near the
energy-consuming facility. CHP’s inherent higher efficiency and its ability to avoid
transmission losses in the delivery of electricity from the central station power plant to the
user result in reduced primary energy use and lower greenhouse gas (GHG) emissions.

Fig:6 Waste Heat to Power Diagram.

7.1 Power Generation

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Generating power from waste heat typically involves using the waste heat from
boilers to create mechanical energy that then drives an electric generator. While these power
cycles are well developed, new technologies are being developed that can generate
electricity directly from heat, such as thermoelectric and piezoelectric generation. When
considering power generation options for waste heat recovery, an important factor to keep in
mind is the thermodynamic limitations on power generation at different temperatures. The
efficiency of power generation is heavily dependent on the temperature of the waste heat
source. In general, power generation from waste heat has been limited to only medium to
high temperature waste heat sources. However, advances in alternate power cycles may
increase the feasibility of generation at low temperatures. While maximum efficiency at
these temperatures is lower, these systems can still be economical in recovering large
quantities of energy from waste heat.

7.2 Generating Power via Mechanical Work:

Steam Rankine Cycle

The most frequently used system for power generation from waste heat involves
using the heat to generate steam, which then drives a steam turbine. A schematic of waste
heat recovery with a Rankine cycle is shown in Figure. The traditional steam Rankine cycle
is the most efficient option for waste heat recovery from exhaust streams with temperatures
above about 650-700°F [340-370°C]. 20 At lower waste heat temperatures, steam cycles
become less cost effective, since low pressure steam will require bulkier equipment.
Moreover, low temperature waste heat may not provide sufficient energy to superheat the
steam, which is a requirement for preventing steam condensation and erosion of the turbine
blades. Therefore, low temperature heat recovery applications are better suited for the
organic Rankine Cycle or Kalina cycle, which use fluids with lower boiling point
temperatures compared to steam.

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Fig 7 : Steam Rankine Cycle

8. Heat generation from wax by means of solar

The principle of operation of multipurpose solar waste heat recovery system is
illustrated. The solar rays penetrate through the glass covers and get absorbed by blackened
metal tray kept inside the collector. The solar radiation entering the box is of short
wavelength. This shorter wavelength gets converted to longer wavelength after penetrating
the glass cover. The re-radiation from absorber plate to outside the box is minimized by
providing the glass cover. The loss due to convection is minimized by making the system
air-tight by providing a rubber strip all around the glass cover. With this type the system is
placed in the sun, the blackened surface starts absorbing the sun rays and the temperature

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inside the box starts rising to the required level. The temperature attained is 60 c and the
time taken is about 1hour. The heat is stored by the PCM (paraffin wax) through out the day.
After the sunset the heat stored in the PCM is utilized by means of supplying water through
the collector and hot water is obtained. The PCM material is packed inside the solar
collector by means of aluminium tubes. This is how the waste heat from wax is utilized by
means of solar energy.

9. Advantages and disadvantages of waste heat recovery

9.1 Advantages :
a) Reduces energy costs: All recovered waste heat directly replaces purchased
energy,thereby reducing energy costs.

b) Reduces operating costs: Since waste heat recovery reduces energy costs and often also
reduces capital costs, it reduces operating costs.

c) Reduces environmental impact: Because all waste-heat recovery directly replaces

purchased energy, it also reduces the environmental impact on air and water.

d) Reduction in Pollution : As for producing the same amount of energy the fuel / input
required is less there will be less exhaust of gases such as CO and therby reducing emission
of pollutants

e) Reduction in equipment sizes :

Waste heat recovery reduces the fuel consumption, which leads to reduction in the
flue gas produced. This results in reduction in equipment sizes of all flue gas handling
equipments such as fans, stacks, ducts, burners, etc[2].

9.2 Disadvantages
a) Capital cost: The capital cost to implement a waste heat recovery system may outweigh
the benefit gained in heat recovered. It is necessary to put a cost to the heat being offset.

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b) Quality of heat: Often waste heat is of low quality (temperature). It can be difficult to
efficiently utilize the quantity of low quality heat contained in a waste heat medium. Heat
exchangers tend to be larger to recover significant quantities which increases capital cost.

c) Maintenance of Equipment: Additional equipment requires additional maintenance cost.

d) Units add addition size and mass to overall power unit:Especially a consideration on
power units which are on vehicles.

10. Applications

Traditionally, waste heat of low temperature range (0-120 °C, or typically under 100
°C) has not been used for electricity generation despite efforts by ORC companies,[citation
needed] mainly because the Carnot efficiency is rather low (max. 18% for 90 °C heating and
20 °C cooling, minus losses, typically ending up with 5-7% net electricity). In general, waste
heat below 100 °C could be used for the production of bio-fuel by growing of algae farms or
could be used in greenhouses or even used in Eco-industrial parks.

Waste Heat of medium (120-650 °C) and high (>650 °C) temperature could be used
for the generation of electricity or mechanical work via different capturing processes.

Waste heat recovery system can also be used to fulfill refrigeration requirements of a
trailer (for example). The configuration is easy as only a waste heat recovery boiler and
absorption cooler is required. Furthermore only low pressures and temperatures needed to be
handled.

Thermal energy storage technologies store heat, usually from active solar collectors,
in an insulated repository for later use in space heating, domestic or process hot water, or to
generate electricity. Most practical active solar heating systems have storage for a few hours
to a day's worth of heat collected.

Energy storage has great potential for providing the means for efficient use of
various forms of energy being wasted in the industry, homes, and large building to use
renewable energy sources, which includes solar, wind, geothermal, and tidal. In addition,
energy storage systems provide efficient means for matching of power generation and

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demand, and the energy is recovered during low load periods and the energy is recovered
during peak load periods.

The storage of thermal energy as latent heat of fusion has attractive features over the
sensible heat due to its high storage density and isothermal nature of storage process at
melting point temp. Solid-liquid transformation is most commonly utilized and the energy
stored could be discharged at a constant crystallization temperature. However, most of the
solidphase materials usually have low thermal conductivity. Therefore, during the
discharging process, as a material solidifies onto the heat transfer surface, high thermal
resistance is obtained.

11. Conclusions

• Recovering engine waste heat can be achieved via numerous methods. The heat can either
be reused ‘within the same process or transferred to another thermal, electrical, or
mechanical process.

• Waste heat recovery entails capturing and reusing the waste heat from internal

combustion engine and using it for heating or generating mechanical or electrical work.

• The waste heat recovery leads to less production of pollutants like NOx andSO2

during creating the same amount of power.

• It would also help to recognize the improvement in performance and emissions of

the engine if these technologies were adopted.

References

1. Cook, E.,“The Flow of Energy in an Industrial Society”, Scientific American 225(4), pp.

135-141.

2. D.A.Reay, “ Heat Recovery Systems” , London 1979.

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3.Cecilia Arzbaecher, “ Industrial Waste Heat Recovery ”,Benefits and Recent

Advancements in Technology and Applications .
4. Upendra S Gupta, “ A New Approach to Waste Heat and Pressure Energy Systems” ISSN
2249-5762.

5. Wikipedia

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