ME-113 · Thermodynamics
Waste Heat Recovery from Industry
A thermodynamics review of industrial waste heat recovery across cement, steel, and food sectors, comparing heat exchangers, ORC systems, and regenerators against real case data.
ME-113 Thermodynamics · May 12, 2025
Instructor: Dr. Ernest Thurlow
Course
ME-113 Thermodynamics
Topic
Waste Heat Recovery
Date
May 12, 2025
Format
Research Paper
Topic Overview
Up to 50% of industrial energy is lost as waste heat through exhaust gases and hot surfaces. This study surveys how three sectors — cement, steel, and food — recover that heat to cut fuel use and emissions, framed as a direct application of the Second Law of thermodynamics.
Objective
Assess the current status, established technologies, and viability of industrial waste heat recovery (WHR), then make sector-specific recommendations.
Method
A literature-based review comparing three WHR technologies — heat exchangers (most widely used and economical), Organic Rankine Cycle systems (suited to medium-temperature 150–230°C waste heat), and regenerators (for high-temperature cyclic operations) — against real industry case data.
Key Insights
Cement kiln exhaust and clinker coolers can meet roughly 30% of a plant's internal electricity needs, generating 5–9 MW per plant. In steel, ORI Martin in Italy recovers electric-arc-furnace exhaust to generate 2.2 MW. Across sectors, WHR retrofits typically pay back within 3–5 years, making the case as much economic as thermodynamic.