Waste Heat to Power (WHP)

The energy and process-intensive industries generate a valuable byproduct that should recycle back to the user power generation. The byproduct is waste heat, and there is an immense volume per facility that either overlooks or devalues this byproduct. 

Waste Heat to Power (WHP) is the process that generates power from waste heat process without adding any fuel. The power recycled can be electrical, or steam or district energy or a combination of all of the three resources. The district energy can be hot water, heating, or cooling.

Bottoming-cycle cogeneration process is another term for the WHP process.

RAI offers the full spectrum of cogeneration cycle processes. (Topping and Bottoming Cycles).

The US Department of Energy (DOE) estimates WHP can generate over 1.5 GW of electricity in the U.S "Not counting the Topping cycle opportunity." 

According to "The Heat is Power Association (HiP) "which RAI is a proud member state:

Waste Heat to Power (WHP) is the process of recovering waste heat and using it to generate power with no combustion and no emissions. WHP systems use the same technologies deployed in a number of industries, including the geothermal industry.  Anywhere there is an industrial process that involves transforming raw materials into useful products – steel mills, paper plants, refineries, chemical plants, oil and gas pipelines, and general manufacturing — heat is wasted as a byproduct. This waste heat is produced whenever the operation is running, often 24 hours a day, seven days a week, 365 days a year. If not recovered for reuse as lower temperature process heat or to produce emission-free power, the heat will dissipate into the atmosphere, a wasted opportunity.

WHP helps reduce energy costs for industrial processes. By using the waste heat to generate emission-free electricity, industrial users can put wasted energy back into the process that created it, route the power somewhere else in the facility, or sell it to the grid to support clean energy production, distribution, and use.

RAI defines WHP as a Power Recycling to reflect our Same Fuel XTRAi Power® approach where we leverage our integrated technologies to satisfy the customer's unique applications. The following are some applications:

  • Blast Furnaces & Foundries: Iron, Steel, Aluminium Smelting

  • Refineries, Petrochemicals, Oil/Gas, Bioenergy

  • Mineral Rotary Kilns: Cement, Gypsum, Titanium Oxides, Magnesium Oxides, Borax

  • Bricks/Ceramic/Glass Tunnel Kilns

  • Incinerators/Thermal Oxidizers/Cooling Tower/Dryers

  • Natural Gas Pipeline Compressor Station

  • Engine (Reciprocating/Turbine)

WHP benefits:

  • Plant OpEx Reduction

  • CO2 Intensity Reduction

  • Purchased Power Reduction

  • Plant Reliability Enhancement

  • Mitigates the Volatile Cost of Power 

RAI Power Recycling package capacity range from 500 KW - 15 MW.

Topping Cycle Cogeneration 

Initially, the process produces electricity from a single source of energy then recover the byproduct to district energy. The cycle simultaneously/sequentially uses power & heat from the same source.

RAI Topping Cycle Cogeneration capacity range: 200 KW - 10 MW.

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