Waste Heat Recovery – Technologies and Opportunities in the Industrial sectorPradeep Kumar Dadhich, PhDDirector| GUIDe - Energy and ResourcesDeloitte Touche Tohmatsu India Private Limited

Three Essential Components are required for Waste Heat Recovery

Barriers and Research, Development, and Demonstration Needs Identified for Promoting Waste Heat Recovery Practices

1) Costs2) Temperature Restrictions3) Chemical Composition4) Application specific Constraints5) Inaccessibility/Transportability

Costs

• Long Payback Periods• Material Constraints and Costs• Economies-of-Scale• Operation and Maintenance Costs

Temperature restrictions

• Lack of a Viable End Use• Material Constraints and Costs• High temperature• Low temperature• Thermal cycling

• Heat Transfer Rates

Chemical Composition

• Temperature Restrictions• Heat Transfer Rates• Material Constraints and Costs• Operation and Maintenance Costs• Environmental Concerns• Product/Process Control

Application-specific Constraints

• Process-specific Constrains• Product/ Process Control

Inaccessibility/Transportability

• Limited Space• Transportability• Inaccessibility

Research, Development, and Demonstration Needs for Addressing Waste Heat Recovery Barriers

Examples of Waste Heat Sources and End-Uses

Furnace Efficiency Increases with Combustion Air PreheatFurnaceOutlet Temperature

Combustion Air Preheat Temperature 204°C 316°C 427°C 538°C 649°C

1,427°C 22% 30% 37% 43% 48%

1,316°C 18% 26% 33% 38% 43%

1,204°C 16% 23% 29% 34% 39%

1,093°C 14% 20% 26% 31% 36%

982°C 13% 19% 24% 29% 33%

871°C 11% 17% 22% 26% 30%

760°C 10% 16% 20% 25% 28%

Factors Affecting Waste Heat Recovery Feasibility1) heat quantity2) heat temperature/quality

a. Heat Exchanger Area Requirementsb. Maximum Efficiency for Power Generationc. Temperature and Material Selection

3) composition4) minimum allowed temperature5) operating schedules, availability, and other logistics

Heat Exchanger Area Requirements

Maximum Efficiency for Power Generation: Carnot Efficiency

Temperature Classification of Waste Heat Sources and Related Recovery Opportunity

Constraints on Energy Efficient Technology Deployment

Consumers needs reliable information to make informed decisions

Benchmarks for energy efficiency

Lack of energy performance rating tools

Supply Chain Issues & Constraints

Availability of Trained manpower

Institutional barriers

Policy Framework (local, regional, national)

Financing options

Regulatory Framework

Smart Grid

Building energy efficiency

Waste heat utilization

HVAC technologies

Supply side efficiency

16

Favorable Neutral Unfavorable

Summary of the constraints and key dependencies

Energy Efficient Technologies in India- Stages of Market Development

Stages of EE Market Development

Boilers

Smart Grid

VFD/Drives

EE motors

HVAC

Waste to Energy

Solar Thermal

Biomass Combustion

Energy efficient buildings tech.

Clean coal technologies

RE Technologies Evolution

Key Policy & Regulatory Drivers

Grants

Carbon Trading

PAT/Ecerts

Tax Incentives, Accelerated Depreciation,

Capital Subsidy

Key Financing & Supply Chain Activities

Demonstration ProjectsScale Up & Supply Chain

Consolidation

ESCO Project Development

PPP models

Investments in Equipment Manufacturing

Balance Sheet/ Project FinancingUtility financing

Venture Capital Investments

Project Financing

Technology Development Market Incubation Market Commercialization Market maturity

DSM framework

Heat Exchangers

Compressors

Led Lighting

PumpsEE Lighting solutions

PE Investments

Public procurement system

Thermal storage

Thank You