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MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA In India, typical cement production plants have production capacities ranging from 2,000 to 10,000 metric tonnes per day, with energy consumption ranging from 3.5 to 5 GJ per ton of clinker produced (of which 10%-15% is in the form of electricity). As an indication, the power that can be produced by an ORC system in a typical cement making process can range from 0.5 to 1 MW per kiloton per day of clinker production capacity (assuming heat recovery is happening from both kiln and cooler waste flows). Using these figures, it can be estimated that the energy produced by an ORC can account for around 10%-20% of the total electricity demand by the cement plant. iron and steel industry In steel production and processing industries, there are multiple waste heat sources where energy recovery with the ORC is possible. Some of these sources include waste heat from rolling unit, forging unit, strip processing unit, heat treatment unit, blast furnaces, sinter, electric arc furnaces etc. The temperature range of exhaust gas from the reheating furnaces (typically between 350°C and 650°C) enables the use of thermal oil as a carrier for the organic heat transfer fluids used in ORC cycles. While waste recovery from clean gaseous streams in the industry is common, heavily contaminated exhaust gases from coke ovens, blast furnaces, basic oxygen furnaces, and electric arc furnaces that are particularly used in this sector, continue to present a challenge for economic waste heat recovery. glass industry Installations of glass manufacturing are divided into two main types: y Plants for producing flat glass y Plants for producing hollow glass Glass production involves melting and refining of the raw materials, a process that takes place at high temperatures requiring very high energy inputs. The unused heat supplied for glass production can be found in the combustion gas exiting the oven, and this gas can provide the required heat for the ORC system to generate electricity (via an intermediate thermal heat recovery circuit). Glass production processes can vary depending on the kind of product (float or hollow glass) or the fuel employed (methane, etc.) or the raw materials used or the production capacities etc. This makes it difficult to develop a general rule of thumb to assess the quantity of power that may be produced by ORC systems through waste heat recovery. However, the exhaust gas temperatures are relatively high (400°C - 500°C), that may lead to high conversion efficiencies (up to 25%) for ORC systems, with related economic advantages. b. internal combustion Engines (icE) and gas turbines9 Internal combustion (IC) engines and gas turbines typically have thermal efficiencies in the range of 20 to 50%. A large part of the energy produced by combustion of the fuel gets dissipated in the exhaust gases and jacket cooling. The exhaust gases often have a temperature level above 300°C, and thus, are suitable as heat input sources for ORC systems. Also the hot air used in the jacket for cooling having temperatures around 90°C, can also be used or integrated with an ORC system. In this manner, the total efficiency of the combined system (IC engine + ORC) can be substantially improved. Approximately 10% supplementary electric power can be generated from the same fuel input. Another application of the Organic Rankine Cycle is to use the waste heat from the gas turbines installed in compressor stations for running huge compressors that in turn maintain the pressure of these gases flowing in the pipelines. By the end of 2009, within North America alone around 75.5 MW of waste heat recovery plants of such type were commissioned at different compressor stations.10 c.renewable energy power plants11 The ORC technology can be successfully integrated into renewable energy power plants, such as solar, geothermal and biomass fired units. 9 ORCycle, Turn Waste Heat into Electricity by Using an Organic Rankine Cycle, April 2011 http://www.orcycle.be/publicaties_bestanden/ Paper1_2nd%20ECP%20ORC_final.pdf 10 ICF International, Status of Waste Heat to Power Projects on Natural Gas Pipelines, November 2009 11 ORCycle, Turn Waste Heat into Electricity by Using an Organic Rankine Cycle, April 2011 http://www.orcycle.be/publicaties_bestanden/ Paper1_2nd%20ECP%20ORC_final.pdf 12PDF Image | ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA
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