Waste Heat

Every year, billions of dollars of energy are thrown away as waste heat.

Heat is the natural by-product of energy conversion processes; both conversion of primary fuels to work or energy, and conversion of energy to work. Of the 100 quadrillion BTU’s of energy the US consumes every year, 50 percent to 60 percent is lost as waste heat.

Though higher temperature waste heat in large quantities is often re-used to perform work or provide heat to buildings and processes, currently lower temperature heat is lost. Before the GEN4 system, no technologies were efficient enough to convert low grade waste heat to electricity. It was mostly discarded in cooling towers, ponds, the atmosphere, or discharged into the sewer.

In industrial settings this lost heat, both high temperature and low temperature, is significant. In 2004, the U.S. Department of Energy released a study, “Industrial Loss Reduction and Recovery in Industrial settings” that found that almost 2 quadrillion BTUs of energy could be recovered from industrial waste heat.

According to the DOE…. Waste Heat is the #1 savings opportunity for industry: ~$6 billion/yr loss

According to the EPA…almost 60% of heat lost is low temperature (<350°F)

Companies are working hard to find solutions that increase their efficiency, reduce energy costs, and minimize their carbon footprint. More efficient lighting, variable speed drive motors, sensors, automation, and more efficient boiler and steam systems all help to reduce energy usage and reduce costs. But even if all of these efforts are implemented, the single major opportunity to reduce base energy costs is to recover value from waste heat.

Ener-G-Rotors’ technology creates new opportunities for waste heat recovery

Ener-G-Rotors’ technology uses this discarded waste heat as “free fuel” for electrical production. Heat is typically converted to electricity using a steam cycle, organic Rankine cycle, or a Kalina cycle. In the past, the turbine has been state of the art for these cycles. Unfortunately at low temperatures or small sizes the turbine is not efficient enough to be economical. A highly efficient expander to replace the turbine alters the economics of generating electricity from heat, creating a market for smaller, lower temperature installations, which match many of the post process waste heat streams found in industry. Low pressure steam, steam condensate, and hot water can now bring additional value to your operation, saving energy, money, and the environment.

Ener-G-Rotors can generate electricity at temperatures and size ranges that are not possible using current technologies.