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Waste heat from turbines and engines used in industrial applications along with waste heat from industrial processes are exceptionally abundant sources of energy. If even a fraction of this waste heat could be economically converted to useful electricity, it would have a tangible and very positive impact on the economic health, energy consumption, and carbon emissions in the U.S. manufacturing sector. The current waste heat recovery technologies, including Organic Rankine Cycles (ORCs) and thermoelectrics, are technically feasible but economically unattractive. This limits their current use to a small number of niche applications. ORCs operate by transferring heat from the source through an evaporator to boil a fluid and create vapor that is expanded across a turbine or other work extraction device. This creates shaft power that can be easily turned into Current Concept schematic of direct evaporator for Organic Rankine Cycle Energy Efficiency & Renewable Energy INDUSTRIAL TECHNOLOGIES PROGRAM Modifications and Optimization of the Organic Rankine Cycle Improved Recovery of Waste Heat in Industrial Processes Benefits for Our Industry and Our Nation GE has more than 1,800 simple cycle gas turbines installed in North America and Europe that cumulatively generate more than 60 GW of electrical power. If 20% of this installed base were retrofitted with the proposed ORC technology, 3 GW of additional electrical power could be produced, which would effectively utilize 90 trillion Btu of waste heat per year. These energy savings represent CO2 emission savings of 4.8 million metric tons, and economic savings of $630 million. An anticipated additional economic benefit of this research effort is a reduction in the costs of ORC technology, which will provide greater returns on investment than previous ORC systems. Applications in Our Nation’s Industry This technology will be initially retrofitted for waste heat recovery in engines and turbines. ORCs can be used in waste heat recovery applications for a broad range of industries, including metals and minerals manufacturing, refineries, chemical processing plants, concrete plants, iron smelters and a vast array of other industrial processes. electrical power through a generator. limitations in ORCs have led to inefficient systems that offer only marginal economic benefits. These limitations stem from the use of a secondary heat transfer loop in most commercial systems to offset safety risks. This secondary loop creates additional costs for each unit, increases the opportunity for component failure, and reduces the conversion efficiency of the system. To address these problems, researchers are working to develop advanced and cost- effective ORCs. The research team will leverage previous research in advanced ORCs to develop a new direct evaporator technological solution that will reduce the ORC cost by up to 20%; enabling the rapid adoption of ORCs for industrial engines and turbines. Boosting the productivity and competitiveness of U.S. industry through improvements and environmental performance

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