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1. INTRODUCTION A considerable amount of heat is wasted in many industrial plants employing thermal processes. Many industrial processes need a cooling system, like in the treatment of exhausted gases. This equipment involves additional investments and operation and maintenance costs. Waste heat recovery solutions have been developing since many years, both for thermal users and power generation. If certain quantity and quality requirements of the waste heat are met, it can be economically convenient to install an Organic Rankine Cycle (ORC) – a closed cycle working with an organic fluid in order to produce electricity. In the last ten years, many ORC turbines have been installed to recover heat from industrial processes, such as cement kilns, metallurgy processes, flat glass plants, gas turbines and internal combustion engines. This application can be considered an excellent example of energy efficiency measure, because companies that have made these investments have reduced their electricity consumption, with no additional use of primary energy. Please find below a simplified scheme of a heat recovery system (fig. 1). Figure 1: heat recovery scheme On January 2010 the first European project on mapping the potential for heat recovery with ORC systems in energy intensive industries (in a pilot area) started. This project, funded by the LIFE + program (LIFE08 ENV/IT/000422 acronym "H-REII"), had the goal of promoting policy and governance actions that would support waste heat recovery for power generation in energy intensive industries and quantify the potential CO2 savings. The HREII DEMO project (LIFE10 ENV/IT/000397) is the continuation and implementation of the H-REII project aiming at: • developing the first prototype of ORC heat recovery plant from EAF (Electric Arc Furnace) in the steel industry completely integrated in a fumes treatment cleaning system; • promoting EU policy and governance actions for incentivizing waste heat recovery for power generation, reducing CO2 emissions by the valorization of process effluents in Energy Intensive Industries. Waste heat recovery for power generation (WHRPG) in energy intensive industries by means of ORC is technically feasible: WHRPG plants with ORC technology are operating in the cement, steel and glass industry and in the natural gas transmission and storage sector. An evaluation of the potential electricity generation with this technology was carried out at European level. Industrial processes considered are: clinker production in the cement industry, Electric Arc Furnaces (EAF) and reheating furnaces for hot rolling mills in the steel industry, flat glass furnaces and gas turbines in gas transmission and storage sector. It has been estimated a theoretical potential of about 2.5 GW of ORC gross power. The heat source is provided by the industrial process, whose operating hours depend on the market fluctuations. Considering 8 000 operating hours a year, ORC plants can generate almost 20 TWh of electric energy. This value represents the 4.8% of the total electricity consumption of EU industry in 2009 and implies avoided emissions of almost 7.5 million tonnes of carbon dioxide 1. Moreover, ORC manufacturer are developing waste heat recovery projects in other industrial processes, particularly in metallurgy. 1 Considering different emission factor for every EU members: Source: European Environmental Agency, 2010 3PDF Image | ORC WASTE HEAT RECOVERY IN EUROPEAN ENERGY
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