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Energy is a critical input in any industrial process, and thus directly determines to a large extent, the environmental impact of the manufacturing process and the products of a any company. Most of the production processes involve heat energy that is generally produced by burning fossil fuels, as prime source of energy. Such production processes are inherently energy inefficient, thereby losing a significant amount of heat to equipment inefficiencies. This study focuses on waste heat recovery, especially the application of Organic Rankine Cycle (ORC) technology in the industrial sector in India. ORC is a technology that operates similarly as the Steam Rankine cycle, except that the former uses an organic working fluid instead of steam. This organic working fluid has a lower boiling point and a higher vapour pressure than water, and is, thus able to use low temperature heat sources to run a turbine for power generation. ORC technology, although new to India, finds some very successful installations in the country. There are a few installations in India based on this technology, notably a 4 MW waste heat recovery plant by UltraTech Cements in Andhra Pradesh, India1 and the 125 KW system installed in Pune by Thermax India Ltd. and the Department of Science and Technology of the Government of India. The latter installation uses the steam generated from solar parabolic troughs during the sunny days, in hybrid mode with biomass boiler during low radiation hours. There are two more installations by Thermax Limited, only for experimentation and research purposes - one in house installation since 2010 and the other supplied to IISc, Bangalore to be commissioned at their new campus. The reasons for such low penetration of this technology in India are the low overall conversion efficiency of the system to convert the heat from external source to electricity (owing to low waste heat source temperatures), the high system cost, the lack of indigenous manufacturing capability and the lack of proper incentives. In addition, most opportunities for the deployment of the technology exists currently for waste to heat recovery than for stationary applications that use biomass or geothermal energy directly. This is because both biomass (except bagasse based systems) and geothermal energy are not as popular 1 The Waste heat recovery project installed at Saint Gobain glass manufacturing facility in Tamil Nadu uses the Steam Rankine cycle technology. in India as solar or wind energy. In the solar thermal installations, as a technology that is gaining a solid foot in the Indian energy scenario, ORC can be used to exploit the medium to low temperature steam to generate electricity. Bagasse based cogeneration systems that are quite common in India, also have a promising future for ORC installations in India. In India, there are many industries, as mentioned below, where the low temperature heat is expelled in the atmosphere without putting it to any practical use. On the other hand, the ORC technology has been commercially utilized in these sectors, especially in the developed world, to extract this “waste” heat. y Industrial waste heat recovery applications (Iron and Steel, Cement and Glass) yInternal combustion engines (ICE) and gas turbines y Renewable energy power plants (solar thermal, biomass and geothermal) y Heat recovery from high temperature heater exhaust used in process such as textile, edible oil refineries, etc.” The total potential of electricity generation from ORC technology in India, including all the sectors, has been assessed during this study to be roughly around 4.4 GW by 2017. This potential is around 574 MW in the Iron and Steel industry, 35 MW in the Glass industry, 148 MW in the Cement industry, 1.4 GW in the solar thermal industry and 2.4 GW in the Biomass industry all till 2017. The potential of using this technology is not considered in the internal combustion engines and the gas turbines, both of which are used for captive power generation as there is no reliable aggregate data for such installations in India, and thus, a detailed sector wise industry analysis is required to explore further it. Unless the total potential of geothermal energy is assessed, the potential for ORC applications in this sector cannot be determined. Also the Indian biomass sector that although has still to go a long way, holds a promising future for stationary ORC applications, but currently the absence of detailed data on this sector, makes such an assessment impossible. It must be noted, as mentioned earlier, that this biomass sector excludes the bagasse based electricity generation and the cogeneration units. It is needless to mention here that if a quarter of this total potential is realised, then the capital cost and the climate impact of building several new thermal power units can be avoided apart from iPDF Image | ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA
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