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Industrial processes are currently responsible for almost 26% of European primary energy consumptions (275 Mtoe/yr). Furthermore, most of the energy sources that drive the industrial sector are fossil fuel based. Every industrial process is characterised by a multitude of waste heat streams at different temperature levels whose recovery would undoubtedly contribute to the enhancement of the sustainability of the industrial sites and their products. Waste heat recovery systems can offer significant energy savings and substantial greenhouse gas emission reductions. For the latter to materialise technological improvements and innovations aimed at improving the energy efficiency of heat recovery equipment and reducing installation costs should take place. This paper outlines the opportunities and the potential for industrial heat recovery in the European Union by identifying and quantifying primary energy consumption in the major industrial sectors and their related waste streams and temperature levels. Through a systematic analysis considering waste heat and Carnot’s potential estimation, detailed results are given for all industrial sectors, temperature ranges and EU countries. The ‘big picture’ is rather promising with regards to the estimated total waste heat potential. The research presented in this paper has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 680599. Aspects of the work are also funded by the Centre for Sustainable Energy Use in Food Chains (CSEF). CSEF is an End Use Energy Demand Centre funded by the Research Councils UK, Grant No: EP/K011820/1.

In the European Union (EU), industrial sectors use 26% of the primary energy consumption and are characterized by large amounts of energy losses in the form of waste heat at different temperature levels. Their recovery is a challenge but also an opportunity for science and business. In this study, after a brief description of the conventional Waste Heat Recovery (WHR) approaches, the novel technologies under development within the I-ThERM Horizon 2020 project are presented and assessed from an energy and market perspectives. These technologies are: heat to power conversion systems based on bottoming thermodynamic cycles (Trilateral Flash Cycle for low grade waste heat and Joule-Brayton cycle working with supercritical carbon dioxide for high temperature waste heat sources); heat recovery devices based on heat pipes (flat heat pipe for high grade radiative heat sources and condensing economizer for acidic effluents). European Union’s Horizon 2020 research and innovation programme, the Centre for Sustainable Energy Use in Food Chains (CSEF) and the Engineering and Physical Sciences Research Council (EPSRC) funded project ‘Optimising Energy Management in Industry-OPTEMIN’