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ORC WASTE HEAT RECOVERY IN REFINERIES AND CHEMICAL Process

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ORC WASTE HEAT RECOVERY IN REFINERIES AND CHEMICAL Process ( orc-waste-heat-recovery-in-refineries-and-chemical-process )

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ORGANIC RANKINE CYCLE SYSTEMS FOR WASTE HEAT RECOVERY IN REFINERIES AND CHEMICAL PROCESS PLANTS John S. Meacher Mechanical Technology Incorporated Latham, New York The design of a low temperature Rankine cycle system using R-113 working fluid for recovery and conversion of process waste heat is described for typical applications in oil refineries and chemical plants. The s6stem is gesigned to produce electric power from waste heat available in a temperature range from 180 F to 400 F. The design of a new ORC turbogenerator uniquely adapted to applications of this type is presented. The unit has been designed for power outputs from 3/4 to 2~ MW and turbine inlet temperatures frQm 170 0 to 260 F. The machine design has eliminated the need for shaft seals, shaft couplings and the usual lube­ oil console normally required for turbine-generator units. Results of prototype tests of a 1 MW unit are presented. A product package and recommended division of responsibilities between purchaser, A&E company and supplier is presented for installations in refineries and process plants. The product package covers the electrical power range from 3/4 to 5 MW and waste heat streams from 20 to 130 million BTU/hr. INTRODUCTION The use of Organic Rankine Cycles (ORC) for the recovery and conversion of low-temperature waste heat has received considerable attention during recent years. The subject of which fluid is best suited for ORC systems has been exhaustively ana­ lyzed, and proponents of about five fluids have established their positions. A few demonstrator systems have been developed and put into service in diverse applications. However, only a small number of such units are now in service, and only a small fraction of the energy-conserving benefits of the concept have been realized to date. This is due in part to the fact that energy costs have only recently risen to the point where such units pro­ vide acceptable return on investment. A second contributing factor may be that the design of ORC equipment has not yet responded to the special needs of the dominant market for ORC systems. The ORC concept has the potential for a broad diversity of applications. These range from glass­ furnace exhaust gases at over 10000F to paper mill cooling-water effluent at l400F. However, two industries have the greatest potential application for ORC low-temperature waste heat recovery systems: the petroleum refining industry and the chemical industry. A study conducted by Resource Planning Asso­ ciates, Inc. [lJ *examined twenty u.S. industries to assess the application potential for ORC systems. These twenty were reduced in number to five Standard Industrial Code (SIC) industries having the highest potential for ORC penetration. These five are shown in Table 1, with the application potential of each. TABLE 1 MARKET POTENTIAL FOR ORC SYSTEMS Technical Market Potential Potential Market Industry (MW) (l1W) Potential Petroleum and Coal Products 1679 1407 67.9 Chemicals and A llied Products 1083 554 26.7 Stone, Clay and Glass Products 267 81 3.9 Paper and A llied Products 15 2 0.1 Primary Metal Industries 178 29 1.4 Proceedings from the Third Industrial Energy Technology Conference Houston, TX, April 26-29, 1981 516 TOTAL 3222 MW 2073 MW 100% Clearly, two industries constitute almost 95 percent of the available market. It should also be noted that of the technical market found in these two industries, 71 percent was judged to be economically A vg. Economic ESL-IE-81-04-90 Avg. % of Market Economic

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