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MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA introDuction Waste Heat by definition is the ultimate heat rejected by any process in which options of all the heat that can be internally used, is exhausted, and any further use may not be economically viable. Waste heat emitted by the process is based on the optimization of resources and is, therefore, strongly dependent on economic parameters. The quantity and quality of waste-heat varies depending on the nature of the process and optimization algorithm used by the respective process licensees. Waste heat can be effectively used as heating energy (steam) and for cooling (air-conditioning by vapour absorption) if there is a scope for such a usage. Effective utilization of waste heat for cooling and heating, although economically attractive, calls for proximity of user points that can utilize this energy. This becomes a bottle neck in many instances. Hence, the conversion of waste heat to electricity becomes one of the most suitable options in this space of waste heat to energy solutions. Electricity generation can be monitored, fed into the grid and also incentivized in a most rigorous manner. The major challenge, however, is the “technology” needed for conversion of waste heat to electricity. Waste heat at temperatures in excess of 450°C and in sufficiently high quantity (>15 million kcal/h or about 5 MWe) makes power generation from such waste-heat system economically viable. This is due to the fact that such conversion systems have their replica in the fossil based power plants using Steam Rankine Cycle (SRC). SRC having proliferated itself as viable heat to power generating option can, therefore, be used in waste heat to electricity applications when the quality of waste heat matches close to the fossil energy systems or the quantity is enough for generating electricity in excess of 10 MW scale. The major challenge, thus, lies when the waste heat quality and quantity becomes lower than what is stated above – let’s call it as medium waste heat systems – and this medium waste heat is the most typical waste heat which needs a different approach. This is given in the following sections. challEngEs in thE mEDium True challenges of waste-heat become more evident when the temperature levels go below 450°C and/ or quantity of the waste heat falls below 10 million kcal/h. The most obvious challenge is due to the lower efficiency of energy conversion devices at lower temperature levels coupled with high cost of heat recovery at such low temperatures. Besides this, the power generation systems for such medium waste heat streams pose limitations in the design and manufacturing of the prime movers and, hence, result in high cost. Therefore finding an economically viable solution for such waste heat to power generation system requires, a multiple approach both at technological level as well as at the policy level. Fortunately the technological advances in the new power cycles have made it viable to explore alternate options in this segment of the waste heat to electricity. There is yet another segment of waste heat which is emitted at lower than 100°C and this requires a different treatment. This is kept out of the scope of the current ambit. It can be safely assumed that 90% of waste heat belongs to the medium category, i.e. less than 300°C and/or about 10 million kcal/h. Merely extrapolating the conventional solution available at the high temperature and high quality will not address this situation, since most of the waste-heat coming from the processes is in this range, and in this range the conventional solutions are not optimal solutions. Hence, the need of the hour is to address this segment with complete focus and concentration, since any solution in this segment will impact large number of industrial processes from small scale to large scale enterprises. This will also result in saving of substantial quantity of fossil fuels that are playing havoc in the Indian economy due to the current account deficit issues mainly due to the increased cost of crude oil import. issuEs rElating to thE ExtraPolation of solution using stEam turBinE BasED systEms Steam turbines are intrinsically designed for high power capacity. There is a fundamental aero dynamic basis for this. The cost per kW of steam turbine is highly functional of the MW rating of the turbine due to the design limitations of the steam turbines for lower capacity systems. To give an example, a 10 MW range turbo-generator costs about INR 7,500 per kW wastE to hEat gEnEration systEms PowEr 32PDF Image | ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA
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