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Chapter 2: The Organic Rankine Cycle in off-grid areas of developing countries, by generating clean power at a lower levelized cost. 2.4 Heat recovery on mechanical equipment and industry processes Many applications in manufacturing industry reject heat at relatively low temperature. In large-scale plants, this heat is usually overabundant and cannot be reused on-site or for applications such as district heating. It is therefore rejected to the atmosphere. This causes two types of pollution (Bundela & Chawla, 2010): ➢ The pollutants (CO2, NOx, SOx, HC) contained in the flue gases can generate health or environmental issues. ➢ The heat rejection can perturb aquatic equilibrium and have a negative effect on biodiversity. Recovering this waste heat can mitigate these two types of pollution. It can moreover generate electricity to be consumed on-site or sent back to the grid. In such a system, the waste heat is usually recovered by an intermediate heat transfer loop and used to evaporate the working fluid of the ORC cycle. A potential of 750 MWe is estimated for power generation from industrial waste heat source in the US (Bailey & Worrell, 2005). Some industries present a particularly high potential for waste heat recovery. Among them, the cement industry, in which 40% of the heat is lost in flue gases. These flue gases are located after the limestone preheater or in the clinker cooler, with a temperature varying between 215 and 315 °C (Engin & Ari, 2005). CO2 emissions from cement industry amount for 5% of the total world CO2 emissions, and half of it is due to the combustion of fossil fuels in the kilns (Bundela & Chawla, 2010). Other possible industries include the iron and steel industries (10% of the CO2 emission in China for example), refineries or chemical industries. Despite their high potential and low cost (1000 to 2000 €/kWe), waste heat recovery organic Rankine cycles only account for 9 to 10% of the installed ORC plants in the world, far behind biomass CHP and geothermal units (Enertime, 2011). 2.5 Heat recovery on internal combustion engines An Internal Combustion Engine only converts about one third of the fuel energy into mechanical power. For instance, for a typical 1.4 liter Spark Ignition ICE, with a thermal efficiency ranging from 15 to 32%, 1.7 to 45 kW are released through the radiator (at a temperature close to 80 - 100°C) and 4.6 to 120 kW through the exhaust gas (400 - 900°C). The heat recovery Rankine cycle system is an efficient means for recovering heat (in comparison with other technologies such as thermo-electricity and absorption cycle air-conditioning). The idea of associating a Rankine cycle to 7PDF Image | Sustainable Energy Conversion Through the Use of Organic Rankine Cycles for Waste Heat Recovery and Solar Applications.
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