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of the total heat input, see Figure 6. The remaining waste energy leaves the system through radiation and convection on the equipment surfaces and temperature in the clinker material. Using the residual heat from the preheater and cooler exhausts to dry and heat-up raw materials and fuels before entering the kiln system optimizes the system efficiency of cement plants. As a result the more realistic thermal efficiency of such kiln systems is increased to between 70 to 80%. However, in cases where the raw material moisture is low, drying requirements are minimized and the heat from the exhaust cannot be valuably reused, the generation of electricity through Organic Rankine Cycles is an interesting option. Even for a small cement plant a power output of 1 to 2 MWel should be feasible. Die casting industry: An average die casting manufacturing plant with 15 casting machines and one central melting furnace produces about 4000 tons aluminum parts per year. For the production of the mentioned output of goods, the plant needs 43200 GJ from gas and 9.8 GWh electricity [8]. In the table below waste heat sources in a die casting foundry are listed. Process Melting Die cooling Hydraulic cooling Part cooling Waste heat source Exhaust gases Water Water Water Waste heat power [kW] 290 120 1200 55 Temperature [°C] 200 40-80°C 50 70 Table 2 Waste heat sources in die casting [8] Aluminum is usually melted in gas fired furnaces. About 32% (in this case 290 kW) of the input energy is wasted as exhaust gas at about 200°C, which makes it interesting as a source for an ORC application. With an ORC efficiency of 12% a power output of about 35 kWel can be expected. However, since the furnace does not run continuously, the electricity would be generated discontinuously as well. This makes it less attractive for ORC. Although there is a large amount of energy rejected by die, hydraulic and part cooling, this energy is at too low temperature levels for ORC application. Conclusion: A large amount of waste heat is rejected at relatively low temperature or at high temperature but discontinuously. Both issues lower the attractiveness of ORC application. This example shows the importance of analyzing each favorite heat-wasting process of the energy intensive industries. Until the end of the project more applications will be analyzed and estimation on the number of potential ORC systems and their range of power will be given. 4. Suitable Working Fluids The selection of an organic working fluid depends on many criteria such as the nature of the heat source, costs of pumps and turbines as well as fluid properties (saturation vapor curve, low freezing point, high stability temperature, high heat of vaporization and density, viscosity, heat transfer characteristics, low environmental impact, safety, good availability and low cost, acceptable pressures, compatibility of materials etc.). Here only a few aspects of working fluid selection will be given, namely • Classification in terms of wet, isentropic and dry fluids • Environmental and health impact • Typical working fluids and operating range • Rough methodology for working fluid selection 4.1. Classification The classification in terms of wet, isentropic and dry fluids can be visualized using the T,s-diagram, see Figure 7. Wet fluids, such as water and R22, have a saturation vapor curve with a negative slope, isentropic fluids have a vertical saturation curve and dry fluids have a positive slope.PDF Image | Application of Organic Rankine Cycles (ORC)
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