Estimation of waste heat and its recovery potential from energy-intensive industries
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ORIGINAL PAPER
Estimation of waste heat and its recovery potential from energy‑intensive industries Bipul Krishna Saha1 · Basab Chakraborty1 · Rohan Dutta2 Received: 20 April 2020 / Accepted: 9 August 2020 © Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract The recovery and reuse of waste heat offers a significant opportunity for any country to reduce its overall primary energy usage. Reuse of waste heat improves the ambient air quality by reducing both industrial pollution and greenhouse gas emissions from industries. This paper presents an estimation of thermal waste heat potential in five energy-intensive industrial sectors (i.e., iron and steel, chemical and petrochemical, paper and pulp, cement, and glass), based on data available in the extant literature and government reports. The findings show that both the chemical and petrochemical industries have the highest theoretical waste heat to power generation capacity for the selected industries. In addition, six individual plant data were collected for case study to determine their waste heat potentials. These estimates were further used to identify the power generation potential using the organic Rankine cycle based on economic advantages, whereby the iron and steel industries were found to have the maximum power generation potential of 66.5 TWh using its waste heat.
Electronic supplementary material The online version of this article (https://doi.org/10.1007/s10098-020-01919-7) contains supplementary material, which is available to authorized users. * Basab Chakraborty [email protected] 1
Rajendra Mishra School of Engineering Entrepreneurship, Indian Institute of Technology Kharagpur, Paschim Medinipur, West Bengal 721302, India
Cryogenic Engineering Centre, Indian Institute of Technology Kharagpur, Paschim Medinipur, West Bengal, 721302, India
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Graphic abstract
Keywords Waste heat recovery · Industrial waste heat · Heat recovery technologies · Energy efficiency · Organic Rankine cycle Abbreviations CHP Combined heat and power plant GHG Greenhouse gas GAIL Gas Authority of India Ltd GWh Gigawatt hour GCV Gross calorific value HPL Haldia Petrochemicals Ltd IWH Industrial waste heat IPCL Indian Petrochemical Ltd MSME Micro, small & medium enterprises NCV Net calorific value ORC Organic Rankine cycle OFC Organic flash cycles PAT Perform achieve and trade RPM Revolutions per minute RIL Reliance industries SEC Specific energy consumption SIPP Static investment payback period TPA Tonnes per annum
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TPD Tonne per day WHRB Waste heat recovery boilers
Introduction Energy consumption today has engulfed our day-to-day lives more than ever before; for instance, both basic needs of illumination along with regulated room temperature are met in residential and industrial processes. Heavy usage of natural resources for generating this energy causes hazardous effects; therefore, rapid advancements are being made to develop ecologically safe, sustainable and reliab
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