www.heatcalc.com | Heat energy is recoverable in huge amounts at industrial facilities across the world and represents an environmentally and economically attractive potential source of clean energy.

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Heat recovery: the least sexy, most
prac3cal, clean energy source around.

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Heat – by defini5on – is a form of energy

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And is available as a byproduct of industrial produc5on
Using heat as an energy source produces zero addi5onal
emissions and oBen offsets fuel, electricity, or other expenses
CEMENT POWER GEN
STEEL COMPRESSION FOOD & BEV
REFINING CHEMICALS
GLASS
Many industries can benefit from heat u5liza5on

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It just doesn’t have the curb appeal
that wind, solar, and other clean
energy technologies do.

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But, industrial heat has uniquely aOrac5ve quali5es
• Using it produces zero emissions, requires no fuel
• OBen available 24x7, day or night, regardless of the weather
• Can directly offset electricity or fuel consump5on
• Accessible, and measurable
• OBen available on-site, and usable on-site or nearby

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It is also available in huge quan55es
Total energy lost as US
industrial heat
(5-13 quadrillion BTU)
=
Total primary energy
consump5on of Italy
(7 quadrillion BTU)
20-50% of US Industrial
energy is lost as heat
Sources: US DOE; Energy Informa5on Administra5on

8. And it’s a versa5le source of energy
Below are the primary 3 op5ons for heat u5liza5on
Warm something up
• Space hea5ng, drying, pre-hea5ng, etc.
Cool something down
• Air condi5oning, refrigera5on
Generate electricity
• Use on-site, or sell to grid

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Heat recovery helps the boOom line
Heat recovery…
“Improves plant
compe33ve
posi3on in the
market”
EBITDA margins at
cement factories
10-15%

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3 components of a waste heat project
• Furnaces
• Ovens
• Kilns
• Incinerators
• Turbines
• Engines
• Boilers
• Excess steam
• Excess hot water
• For warming: heat
exchanger(s), steam or hot
water loop
• For cooling: absorp5on chiller
• For genera3ng electricity: ORC,
thermoelectric, steam turbine,
etc.
• OBen within same site
• Hospital hea5ng & cooling
• Campus hea5ng & cooling
• Food storage refrigera5on
• Lumber drying
• Greenhouse hea5ng
• Combus5on air prehea5ng
• On site electricity
• Grid electricity
2. Recovery unit 3. User
Ideally, heat availability matches
the user’s demand schedule
1. Heat source

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Example: heat for warming
Mul$ple natural gas engines generate
electricity for the grid. The engine heat – which
is a natural byproduct of genera$on – is used in
the district hea$ng loop to warm nearby
buildings. This arrangement is called Combined
heat and power (CHP).
Benefits
+ Operators receive primary energy savings
of 40%
+ Avoided the addi5onal capex of boilers to
supply hea5ng
www.dieselgasturbine.com
District energy loop Building heat Recip engines

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Example: heat for cooling
At an aluminum facility in Dubai, air
condi$oning is required for much of the year.
Absorp$on chillers convert smelter heat into air
condi$oning, which cools the worker areas of
the building.
Benefits
+ Avoided capex on air condi5oning units
+ Avoided cost of electricity from running
the air condi5oning units
+ Reduced electricity consump5on by
242GWh, enough for ~23,000 US homes
hOp://en.energy-changes.com/
Absorp5on chillers Building AC Aluminum plant

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Example: heat for power genera5on
www.zkg.de
Heat at this cement facility is extracted from 3
areas: the rotary kiln, clinker cooler, and
nitrogen oxide removal plant and converted
into electricity with a single steam turbine.
Benefits
+ Offsets 1/3 of the electricity required at
the site
+ CO2 emissions reduced by 30,000 tons / yr
+ Energy price hedging
Steam turbine On-site electricity Cement plant

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Each heat source is unique
Typically, spec sheets or monitoring equipment indicate the
temperature & flow rate of the heat source
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 makes sense of the heat data
By quan5fying the heat available at your source. Online. Free.
10,302 kW
2,256 kW
894 kW
145 kW
954 kW
2,509 kW
4,034 kW
8,393 kW

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HeatCalc has tools to help enable
your project
HeatCalc quan3fies your heat source
• Calculates the amount of heat available in your
source, based on your specific heat inputs
• Provides ideas for what you can do with the heat
• Connects you with the right suppliers and energy
service companies to make your project a reality
A hub of useful heat recovery informa3on
• Example projects / case studies
• Recent heat recovery news
• How to’s and recommenda5ons

17. visit us at heatcalc.com
Enabling heat recovery projects worldwide