Waste Heat Recovery in Industrial Enameling Ovens Using Pilot Scale Thermoelectric Generator: Energy, Economic Feasibility, and GHG Emissions Analysis

This study investigated the potential for energy recovery in vertical industrial enamel ovens using a pilot-scale thermoelectric generator (TEG) system. Enameling processes, characterized by high energy consumption and significant waste heat generation, offer the opportunity to increase energy efficiency. In the scope of the research, the feasibility of converting waste heat into electricity via a TEG system integrated into a vertical enamel oven was investigated, and the economic and environmental impacts of such a system were evaluated. The study calculates the waste heat power in the chimney by analyzing thermal and mechanical energy contributions and demonstrates the sustainability benefits of the proposed system. In addition, the emission analysis examines the effects of different wire and enamel types on CO2 and NO2 pollutant levels. It highlights the impact of material properties and solvent compositions on emissions. In addition, the economic feasibility analysis further strengthens the feasibility of waste heat recovery in industrial operations by highlighting the cost savings achieved by reducing energy dependency. This research shows that energy recovery is important to achieve sustainability goals and integrate manufacturing into Industry 5.0, an industrial revolution that supports sustainable and smart production processes and offers the potential to reduce the environmental impact of industrial processes. The analysis showed that with the TEG system, 410 W of power can be recovered from the waste heat from the industrial enamel oven, saving 3072 kWh of energy per year. It was concluded that the waste heat produced by the industrial enamel oven can be utilized, contributing to the company's electricity needs and reducing CO2 emissions from energy by 1.84 tons per year.