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MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA Heat losses arise both from equipment inefficiencies and from thermodynamic limitations of equipment and processes2. Heat is generated by fuel combustion or by chemical reaction in a process in which part of the heat generated is used up, and the rest of the heat is “dumped” into the environment by means of an exhaust gas or steam. Although the total energy lost in waste gases/steam cannot be fully recovered3, much of the heat could be recovered and be used for various useful and economic purposes. This would not only increase the efficiency of the process, but also reduce the fuel consumption, thereby reducing both the running costs and the carbon intensity of the process. Waste heat can be utilized in two forms – utilising the waste heat in thermal applications or converting the waste heat in to electrical energy. Since the conversion of waste heat in to electricity involves efficiency losses at each stage, it is preferred to use the waste heat directly in thermal applications wherever possible, since the latter have comparatively lesser heat losses. In cases where this option is not viable, the waste heat is converted in to electricity. This electricity generated is either consumed within the process or is transferred to the grid. Generation of power from waste heat typically involves the conversion of the (otherwise) waste heat to mechanical energy to drive an electric generator. Industries have different processes which in some way or the other involve dumping of heat into the atmosphere in the form of flue gases, hot water, steam etc. Heat can be recovered from these streams and utilized through different thermodynamic cycles to generate power. The most frequently used system for power generation from waste heat involves using the heat to generate steam to drive a steam turbine, a process commonly referred to as the Rankine Cycle, a schematic diagram of which is shown below in Figure 1. 2 U.S. DOE Energy Efficiency and Renewable Energy, Waste Heat Recovery: Technology and Opportunities in U.S. Industry http://www1.eere.energy.gov/ manufacturing/intensiveprocesses/pdfs/waste_heat_recovery.pdf 3 Express India, MEDA Plans to Popularise Waste Heat Recovery Schemes in Industries, January 2008 http://www.expressindia.com/latest-news/meda- plans-to-popularise-waste-heat-recovery-schemes-in-industries/263715/ figure 1: schematic of steam rankine cycle Turbine Electricity Generator Waste heat from Process Condenser Evaporator Pump Exhaust The traditional Steam Rankine Cycle (SRC) has been one the most efficient options for waste heat recovery from exhaust streams with temperatures above 650- 700°F [340-370°C]. At lower waste heat temperatures, this cycle becomes less cost effective because of the following reasons: yLow pressure steam generated from low temperature waste heat requires larger, bulkier and costlier equipment. y Low temperature waste heat does not provide sufficient energy to superheat the steam, which causes steam to condense resulting in the erosion of the turbine blades and other metallic units. For such low temperature waste heat recovery applications, a better technology that may be used is the Organic Rankine Cycle since this cycle uses organic fluids that not only have lower boiling point temperatures than steam has, but also do not corrode the metallic parts of the equipment. the organic rankine cycle (orc) is similar in operation to the steam Rankine cycle, except the fact that the former uses an organic working fluid while the latter uses steam. Typical working fluids include (but not limited to) silicon oil, propane, haloalkanes (e.g. “freons” or hydrofluorocarbons), isopentane, isobutane, toluene etc., that have a lower boiling points and higher vapour pressures than water or steam have. This allows the cycle to operate at significantly lower temperatures — sometimes as low as 150oF [66oC] – a general characteristic of many waste heat streams. In comparison to water/steam that are used in the SRCs, the organic fluids used in ORCs have higher molecular masses enabling compact designs, higher 2PDF Image | ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA
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