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(approximately INR 7.5 million per MW). However, the turbo-generators at 1 MW scale cost about INR 35,000 per kW or INR 35 million per MW, and the cost goes up exponentially over INR 100,000 per kW or INR 100 million per MW at 50 kW scale. The reason for this is both technological as well as of economy of scale. A turbo generator that costs INR 35 million per MW, when coupled with waste heat recovery systems and rest of the plant, results in the cost of power per MW in excess of INR 60 million that is the upper bound in the viability scale of waste heat to power solutions. Below 1 MW scale, the numbers become much more challenging and hence feasibility is practically impossible. Steam turbines and waste-heat systems are fairly matured in terms of technological development and, thus, further scope of reduction in cost is rather limited. Hence, the only feasible solution is to move away from the steam cycle and to explore the alternate options. what is ProPosED Clearly, for this range of waste-heat, a steam based solution would not solve the problem. Alternate power cycles that are optimum for this temperature and capacity, need to be given a thrust to make waste heat to power attractive not only from an efficiency point of view, but also from a financial one. A very fundamental level analysis indicates that moving away from the SRC to other Rankine Cycles, such as the Organic Rankine Cycle and/or the Organic Based Hybrid Cycles (Rankine plus Brayton), would bring feasibility in this range over a period of time. Further, these cycles enable higher system efficiency and more compact equipment. The shift from steam based cycles to other fluids based cycles implies the use of fluids of lower density resulting in much lower equipment size at lower operational temperature ranges. The direct consequence of this is the usage of lower material content per kW of power generated. Ideally a 300°C flue gas generating 1 MW power through a steam cycle would use, say, 25 kg of steam per kW while an equivalent Organic Rankine cycle would use less than 4 kg per kW. Therefore, there is a strong basis for the shift. Besides this, design based on screw expanders or even on simple internal combustion engines, greatly reduce the cost of the equipment. Further these cycles present themselves to multiple level innovations and offer themselves to much higher efficiency possibilities. One more advantage in these advanced cycles is the lower water consumption, and these cycles can be coupled with vapour absorption cooling systems as well to make them water free without any compromise on the efficiency due to the air cooled systems. Such power plants based on organic fluids will be the most attractive option that needs to be explored seriously in India. othEr innovativE solutions in wastE to PowEr systEms Another major component in the waste heat to power scenario is heat recovery devices. Currently these heat recovery devices are designed in a very conventional manner using standard materials. Due to low pressures, there is a high potential to use much lighter weight materials, and also need to be investigated thoroughly to reduce material content, and hence, the costs. This, though may look trivial, calls for a different approach in developing waste heat exchanger designs using thinner tubes and advanced heat transfer extended surfaces that enhance the waste heat transfer to the secondary fluids. nEw moDEl rEQuirED for fastEr ProlifEration of wastE hEat to PowEr tEchnology in inDia The above discussions indicate that the for waste- heat to power recovery based on steam cycles, will not yield the desired results, and hence new cycles mentioned above with appropriate cost reduction measures for the waste heat recovery devices, must be developed. These devices can generate electricity from waste heat sources of temperatures 350°C to as low as 140°C, and have capacities ranging from 1 to 3 MW scale to 50 kW scale. These systems can be then used in not only waste-heat recovery to power conversion from the currently identified sectors, such as Cement, Steel, Fertilizers, Glass and Aluminium, but also can be used in many applications in small to medium scale sectors as well. So much so that such development can become ubiquitous, and hence can be multiplied on a large scale in India. This is the only way that waste heat to power systems can proliferate in India. 33PDF Image | ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA
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