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Heat is Power. Let's Stop Throwing it Away!

Thomas R. Blakeslee, Clearlight Foundation
July 24, 2008  |  23 Comments

High gasoline prices have forced us to make painful adjustments, which may, unfortunately, be just the beginning. The world's dramatically growing energy demands are affecting all energy prices. Coal, Uranium and natural gas prices have all risen dramatically in the past few years and will continue to grow in the future as more and more of the world's population adopts our energy-wasting lifestyle. We are straining the limited resources of our planet.

Power rates are heavily regulated but will soon have to reach shocking levels unless we change our careless ways. Our wasteful energy habits were formed during the many decades before 1973, when oil was less than $3.50 per barrel. At those prices energy was essentially free so we learned to ignore waste. Only 15% of the power of the gasoline you burn in your car goes to move it down the road. The rest ends up as wasted heat, uselessly heating the air. Electric cars are about 75% efficient but they lost out to gas buggies back when gasoline was an insignificant cost.

In 1882, Edison's first electric power plant sold their spent steam for district heating. Efficiency of electric generation reached a peak in 1910 and has been falling ever since as regulated utilities stopped selling their waste heat. Nowadays the norm is to simply discard the extra heat. Thermal power utilities today only deliver 1/3 of the power in the fuel they burn to customers. The other 2/3 is simply discharged as waste heat! This 33%, efficiency level is the same as it was in 1957!

In the 1930s the government tried to encourage electrical generation by granting monopolies to power generators. The rate-setting formula they created actually penalizes efficient generation. If a utility buys less fuel because of better efficiency, their costs are less so rates must come down to cancel any benefit.

To make matters worse, the clean air act makes it dangerous for utilities to make efficiency improvements because it invites regulators to tighten emission controls as conditions for approval. Worse yet, the clean air act regulates the percent of pollutants (PPM) not the amount per kilowatt-hour (kWh) output. Currently, if you double efficiency the amount of pollutants you are allowed will be halved. Pollution standards should be changed to an output-based standard, such as grams per megawatt-hour (MWh) to stop these terrible unintended consequences. (For more how the power monopolies cling to their power, click on each of the bullet points on this page.)

Cooling towers simply discard the wasted heat of a power plant into the air. If a utility today sells steam as Edison did they are not allowed to keep any of the profits because the income reduces their operating expense base! Hot water or steam is a valuable commodity, which could be piped to homes for heating or sold to nearby drying plants, greenhouses, ethanol plants and fish farms. If the laws encouraged sale of excess heat, as they do in Europe, wasteful cooling towers and discharge outlets would be a thing of the past.

Iceland provides an excellent example of the benefits of efficient energy use. It approaches power generation as a complete ecosystem where available heat is used with about 90% overall efficiency. The hot water from its geothermal wells is first used to generate electrical power. If the waste heat were discarded, this would be less than 20% efficient. But the wastewater is instead piped to nearby factories and used for drying fruits and vegetables or to run absorption chillers in a refrigeration plant.

The hot water that exits those applications is still pretty hot so it is sold for district heating to greenhouses and apartment buildings. Next in line are the lower temperature applications like fish farming, snow melting and bathing.

By making use of all of the heat instead of discarding it as waste, the efficiency of the entire system can be 90% or more even though the power plant itself is only 20% efficient! This amazing improvement in efficiency requires nothing more than designing with an expanded awareness that considers synergies that will turn waste into profit. The model for this is all around us in nature where nothing goes to waste.

This new paradigm has been extensively developed as industrial ecology and is closely related to the concept of permaculture. It is a new way of thinking that opens awareness beyond design in isolation to consider the design as part of an interrelated ecosystem. As energy costs increase, we can use this new thinking to maintain a gentler form of our current lifestyle by simply taking advantage of the synergies we have ignored in the past. In Europe they have a $6 billion project called Lo-Bin ($3 billion already EU funded) to develop a 98% efficient geothermal power project based on these principles.

In cases where it isn't convenient to pipe hot water or steam to where it is needed, an ORC generator can convert waste heat to electricity. These generators are essentially air conditioners running in reverse: The heat boils a low boiling point liquid driving a turbine which turns a generator. With minor redesign, an air conditioner can be converted to a waste heat generator that will convert heat to electricity. Small ORC generators based on this principle are just beginning to be released to the market.

Solar thermal heating and hot water has become very popular in China where the cost of rooftop solar collectors has become very competitive. Fifty million rooftops already have solar thermal collectors and the numbers in China are growing by 26% per year. These collectors are mostly arrays of concentric glass tubes with an insulating vacuum between them. A hot water tank provides energy storage. These systems could easily be converted to also provide power generation by just adding a small ORC power generator. Mini-generators are not available yet but they could be very inexpensive high-volume products. Since home air conditioners sell for only US $0.10/watt, they could be a very economical way to generate power in the home from the excess heat when the water is already hot enough. Currently, this excess heat is simply wasted.

Combined Heat and Power (CHP) cogeneration can be done in the home with 85% efficiency. Honda has sold over 45,000 of its Freewatt micro-CHP home heater/generators in Japan. The generator uses a very quiet, natural gas powered, internal combustion engine that has the usual 20% efficiency. The unit is installed in place of your furnace and runs only when heat is needed. When it is running, it puts out 1200 watts of electrical power to run your meter backwards. The 80% "wasted heat" works just fine as a furnace to heat your home!

Most industrial plants that were designed in the days of almost free energy release most of their energy into the air as waste heat. ArcelorMittal has a steel mill in Indiana that they retrofitted to recycle wasted energy. They were able to recover about 250 MW of power, cutting the power consumption of the plant in half! This is like building a new 250-MW power plant that will never need any fuel. The cost of the construction required was less than half of what it would have cost to build a coal power plant. (Watch a video interview with Tom Casten, chairman of RED, the company the worked on this project.)

In the US we don't hear much about cogeneration or CHP but Denmark generates 55% of their electricity this way and Finland and Holland do about 40 percent. When wasted power is recovered we are saved the trouble, expense and pollution of building another power plant to generate that power. If our utilities laws can be changed so that efficiency becomes profitable, we could see a doubling of plant efficiency in just a decade. Since 69% of our greenhouse gas emissions are from heat and power, doubling efficiency could reduce our emissions by 34%. Instead of spending billions of dollars building new power plants, we should be using ecological thinking to put to use the millions of megawatts of heat we throw away every day.

Thomas R. Blakeslee is president of The Clearlight Foundation, a non-profit organization that invests in renewable energy and other socially useful companies and issues cash grants to individuals who are working effectively for change.

23 Comments

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MARIAN NITULESCU
MARIAN NITULESCU
February 10, 2009
If anyone can give me information about how,with minor redisign,an air conditioner ca be converted to a waste heat generator that will convert heat to electricity ,please do it ( small ORC generators)
Jose Delgado
Jose Delgado
July 28, 2008
T. Schmidt is not addictted to energy unless it involves using the energy hog servers that power the internet so he can post his comments. OR the energy consuming sewer system to flush away his STUFF.
So please pratice what you preach and cut yourself from the grid, and buy an out house...do forget the shovel...
Thomas Schmidt
Thomas Schmidt
July 27, 2008
Who's going to pay for it?
The American taxpayers?
Do you really want to save the planet Earth poeple?
Or are your just not "in love" with idea of saving it (us)?
You have to quit energy. Plain and simple, just say no to energy.
For well over 7,000 years, mankind thrived on the planet Earth with out these energies. It has only been in the last 100 year that we have begun to believe, that we cannot live without them.
Sure, people will die off in grate numbers if this is done cold turkey. So take 100 years to reverse it. Only 4.5 billion will die in that 100 years. The same number it has increased since this addiction to energy started 100 years ago.
That would be 45 million dead bodies a year on average. Hey would could burn the bodies to produce energy while we ween ourselves off of energy. There are some really fat people out there that could produce a lot of energy.
Hey! your the ones addictted to energy, not me.
Howard Hull
Howard Hull
July 26, 2008
I am at present living and working in Aktau, Kazakhstan. The whole city is provided with hot water from the local nuke power plant. In really hot summer weather there is no hot water. But plenty in the winter time, as a matter of fact you might not get any cold water.
michael macrumpton
michael macrumpton
July 26, 2008
The author is spot on in his analysis of our energy wasting. Because of the knee-jerk resistance to the ideas of conservation and efficiency I believe the best way to appeal to industry and "conservative" politicians is to focus on the benefits on the bottom line.
I remember as a child being told by my father that when I left the door open in the summer that dollar$ are flying out the door. Somehow that image has stayed with me, and I think if people were more aware of how much cheaper it is to save energy/money than it is to generate it, then expecting efficiency might become the norm.
Perhaps a yearly contest for energy saving ideas with a huge cash prize would be a way to capture the public's imagination...
Jackie Jones
Jackie Jones
July 25, 2008
CHP - whether using fossil fuels or biomass - makes so much sense. There's much more CHP-specific info on the website of one of REW's sister magazines - http://www.cospp.com/

Jackie Jones, Editor, REW magazine
John Gregson
John Gregson
July 25, 2008
Reading about not wasting Heat is interesting, large Power Stations soon should be the old way. Due to line losses only 30% of energy is actually converted to produce Electricity. The rest is wasted power in transmission losses, and heat losses as anyone who has driven past a Power Station should know.

I am partner and Director of Bamford Energy Management Ltd
Trying to inform companies how to reduce their energy use with out really costing, a lot. Most surveys end up with a report, saying 1/3 energy does not need any spend, then little spend, then a major spend.

But except for what has to be spent to start with, soon saving energy reduces costs, and this covers what has being spent.

John Gregson 07796 533 460
TOM WILL
TOM WILL
July 25, 2008
I guess our downfall was the Rural Electrification Act which led to huge power plants and the public not having a sense of where the energy is coming from. Prior to the act, people were using solar, wind, and biomass to produce the energy they needed and had to "work" for it. Conservation and high efficiency were a must and innovation and creativity were abounding. Just look at some very old Popular Mechanics. Now we are trying to get back to independent power generation on the small scale where we left off in the 1930's. We now have 70 year's of catch up to do.
Bama Tecangel
Bama Tecangel
July 25, 2008
"So let's get the capitalists to get off the cheap trick bandwagon of investing in sound bites and products that are already commodities in order to flip their investments to the ignorant for unGodly profits."...

Yeah, that kind of greenspeak will just turn on all the treehuggers and turn off the rest of us that care about solving real problems with real money. I see nothing wrong with capitalism. It dang sure beats all the other alternatives to an economic social structure.
Paul Johnson
Paul Johnson
July 25, 2008
To me this article points out the obvious improvment in technology. Sure cogeneration is more efficient, but it was not around when many power plants were built. All new construction will have this feature because it is more efficient.

Companies will retrofit where it makes financial sense. But sometimes, a new natural gas cogeneration plant (and decommission the old coal plant) makes more sense than trying to retrofit a 50 year old coal plant.

This is the benefit that Bama points out. Capitalism and profits are not evil. Profits forces companies to use the limited capital in the most efficient methods. Withouth profits there are no companies. Without companies, you don't need electricity since no one will make gadgets that use electricity.
nick gogerty
nick gogerty
July 25, 2008
Great article and definitely highlights the need for regulatory change.
Paul Justus
Paul Justus
July 25, 2008
This is an excellent article that shows how our incentive systems are completely backwards. We need to put things in order by adopting the Green Tax Shift -- i.e. Tax Waste, Not Work.
The Green Tax Shift provides a triple dividend by encouraging conservation and less pollution, by stimulation our economy by un-taxing labor and capital, and by reducing the need for government regulation by harnessing the power of an authentic free market to provide the incentives for energy efficiency.

Tax what we burn, not what we earn.
Jeff Kelly
Jeff Kelly
July 25, 2008
Ummm...the author proposes to sell all that "wasted steam" from power plant boilers. You can't quite do that because the power plant needs that steam to be condensed back into water to re-enter the boilers. You can't give the power plant's water away, but you can give away the condensing heat if you keep the water cycle closed. This is sloppy terminology on the author's part.

What the author has right is our waste of waste heat. Consider that the geothermal energy industry is now buying special power generators to extract useful energy from water under 300F:

http://www.utcpower.com/fs/com/bin/fs_com_Page/0,11491,0167,00.html

These machines are basically traditional air conditioning chillers modified to run in reverse. UTC is the parent company of Carrier air conditioning...so here's a new use for a traditional product line.

I would have to think that these devices and other techniques can be applied, with the right incentives, to improve the efficiency of traditional thermal plants as well as large industrial processes with huge ovens, kilns, etc, and sources of waste heat.

It is interesting that the author brings up the nature of federal regulations that create perverse incentives to prevent plant improvements. This issue deserves a closer look. There's much talk about saving the world by having homeowners install PV panels on the roof, but the fact is that industry and gov use 93% of the electricty generated in this country. We have neglected the unglamorous value of improving industrial energy efficiency while badgering housewives to weatherstrip their patio doors.

In the past, the electric utility companies have encouraged much efficiency improvements with incentive programs for their large industrial customers, but these programs have now run out of gas economically. The gov should start heavily incentivizing industrial energy efficiency improvement and take up the intitiative where the utility company incentives leave off.
Bill Batina
Bill Batina
July 25, 2008
This is an excellent article.
Another area where the world is wasting energy is our modern electronics. All of our electronics - TVs, computers, microwaves, etc. have transformers converting line power to low voltage DC to operate. The transformers draw current even when the device is turned off and produce heat as the waste product. Our homes and offices should be wired with additional DC circuits to power our electronics directly without the extra transformers. One or two electronic AC to DC converters could be wired at your breaker panel and then distributed throughout the house using separate wiring and plugs/ recepticals. Our homes / offices would then be ready for direct DC from renewable sources such as solar PV.
Jay Rosenberg
Jay Rosenberg
July 25, 2008
My company has a high efficiency, heat source agnostic turbine (RET). It accept any heat source with sufficient btus: waste heat, solar thermal, Geothermal, on-board fossil fuel engines… It can be built in the U.S. The problem is not the technology, or cost – RET is a fraction of competition. The problem is the difficulty in getting to the decision makers. It is politics in its basest form, you are an outsider, stay outside. Ever try to speak to a significant party in one of Al-Gores organizations? Blakelee is correct that power plants have arcane regulations which economically favor inefficiencies. However, there are solutions (meaning recoup waste heat, profitably). The renewable/ efficiency experts are too conservative, behind the development curve, and politically protective. Unfortunately, this percolates to the top. For example Al Gore's 100% US electricity from renewable in 10 years – equates to achieving only 10% of the US energy need in 10 years. Does 10% in 10 years sound like a solution? My involvement shows that 100% of US energy needs (40TWH/yr) will be achieved in 10 or less years! There are too many trillions of dollar on the table. If Gore were properly advised, he would say 100% of US energy, but he did not get the correct fact sheets, analysis, or introductions. Foreign countries are making leaps the US is not, e.g., a 1 GW wind farms. Renewable energy companies are making too much money – to stop cranking out low efficiency quasi solutions. A solution, means energy costing MUCH less than fossil fuel. Energy solutions will relegate prior (still new) equipment to the legacy pile. Who wants to pay $.15/kWh, when you can get it for $.05/kWh or less? (and my company has at least 2). RENEWABLE Energy, unlike fossil fuel or nuclear is a zero sum game, thus a cut throat process. Ironically, while this process is cutting our throats, it is also destroying our lungs, and planet!
Rick Kolb
Rick Kolb
July 25, 2008
In the past I have voiced criticisms about Mr. Blakeslee, mainly concerning what I perceive to be some carelessness in using numbers to prove his point. In all fairness, I must admit that this article is much better in this regard although there has been some SLIGHT increase in coal plant average thermal efficiencies since 1957 but not enough for me to quibble about. His main point is quite correct, we need to do something useful with the large amount of waste heat generated by power plants of all types.
Sam Weaver
Sam Weaver
July 25, 2008
Great article!

As I think Mr. Blakeslee is aware, our company Cool Energy, Inc. is working on the small-scale distributed solar thermal sector of the CHP space, using evacuated tube collectors for the solar heat gain, and a Stirling engine for the power generation. There are multiple technical and practical reasons for this approach vs the Rankine cycle approach when the scale of the generation is small. Fundamentally, the system provides a building owner with a high solar fraction of space heating in the winter months, with power generation in the summer months. These systems (heating and electricity) are tied together with a controller that uses the heat in the most cost-effective way possible for the user. The target market for these systems are areas with high heating and electricity costs, such as the Northeast and mid-Atlantic regions, where system payback times are twice as fast as for other technologies.

We expect to be doing on-sun testing in Q2 2009, and the prototype engine is running in the lab.

http://www/coolenergyinc.com
eugenio fonck
eugenio fonck
July 25, 2008
Don't buy an new car anymore. If you need one, buy a used one, ore an electric car, or an hydrogen car or an compressed air car. Save the world.
Jonathan Cole
Jonathan Cole
July 25, 2008
To Bama Tecangel:
You wrote:
"Yeah, that kind of greenspeak will just turn on all the treehuggers and turn off the rest of us that care about solving real problems with real money. I see nothing wrong with capitalism. It dang sure beats all the other alternatives to an economic social structure."

That kind of response to my post is irrelevant. I am a capitalist. I have a Masters Degree in Business. I have also been personally utilizing and developing renewable energy systems that include cogeneration for 26 years. My perspective goes way beyond greenspeak to survivalspeak.
Arnold Henerlein
Arnold Henerlein
July 25, 2008
I am elderly aand have been handicapped all my life. and have thought for years we should be using wasrte heat. Let's build thease near cities where we can pipe it with the water system that is already in place.
Arnold Henerlein
Arnold Henerlein
July 25, 2008
I am elderly aand have been handicapped all my life. and have thought for years we should be using wasrte heat. Let's build thease near cities where we can pipe it with the water system that is already in place.
Arnold Henerlein
Arnold Henerlein
July 25, 2008
I am elderly aand have been handicapped all my life. and have thought for years we should be using wasrte heat. Let's build thease near cities where we can pipe it with the water system that is already in place.
Jonathan Cole
Jonathan Cole
July 24, 2008
This is an excellent article. It gets to the core issue of the how the convergence of inefficiency, waste, and primitive design of energy systems are artifacts of the industrial revolution founded on relatively cheap combustion energy fuels.

The unintended side effects of this wastefulness is at the center of the global crisis we now face. What if the answer to these problems is simply to change our industrial and technology-use habits. Will we be too stubborn or self-interested or mired in short-term thinking to take the steps to preserve the Earth, our only home?

Mr. Blakeslee has clearly identified a critical direction for rectifying the energy conundrum. Don't waste anything. Instead turn all energy streams into useful outputs according to their energy content.

Since it has already been so widely demonstrated, there should be no resistance to investment in these systems and technologies. In fact, no matter what non-combustion renewable energy technologies you favor, they all need backup, storage and distribution in order to provide the standard of living to which we have become accustomed.

So let's get the capitalists to get off the cheap trick bandwagon of investing in sound bites and products that are already commodities in order to flip their investments to the ignorant for unGodly profits. Let's focus the investments on practical integration of systems that yield real results instead of paper profits.

We are in an era where the control of the productive resources is in the hands of people whose sole motivation is short-term financial reward. Previously, the concept of product viability and utility (and therefore profitability) were thought to be the foundation of good investment strategies. We must get back to that sustainable approach to capital utilization. While it may be swell to be a Master of the Universe, unless investments yield beneficial results, then we may be on a slippery slope to chaos.
http://lightontheearth.blogspot.com

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Thomas Blakeslee

Thomas Blakeslee

Thomas R Blakeslee’s books have been published in nine different languages. After serving for three years in the U.S. Navy, he earned a degree from CalTech in Pasadena, California in 1962. After working for IT&T in Antwerp, Belgium, he...
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