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International Journal of Scientific & Engineering Research, Volume 3, Issue 10, October-2012 ISSN 2229-5518 Waste Heat Recovery System by Using an Organic Rankine Cycle (ORC) Md. A. A. Mamun, Subrato Biswas Abstract— Though the concept of Power Plants based on the Organic Rankine Cycle (ORC) is the new technology in Bangladesh, it can play a significant role to produce power from various heat sources when other alternatives were either technically not practical or not eco- nomical. These power plants in sizes from 300 kW to 130 MW have demonstrated the maturity of this technology.[6] The cycle is well adapted to low moderate temperature heat sources such as waste heat from industrial plants. This paper represents the feasibility of ORC based power plant in Bangladesh which has been suffering from energy crisis and unable to meet the present demand. The ORC technol- ogy is applicable to heat recovery of steel mills, rerolling mills, cement plants, and offers significant advantages over conventional steam bottoming cycles. One such system, the 2.630 MW Power Plant is now under analysis forecasts at Rahim Steel Mill in Bangladesh. [2] The environmentally friendly power plant is the first to be installed in these types of industries.[2] Key Words— Bangladesh, Gas Engines, Organic Rankine cycle,Organic fluid,Steam turbine,Steel Mill, Waste Heat Recovery. —————————— —————————— 1 1 INTRODUCTION THERE are numerous steel plants in Bangladesh where the utilization of engine exhaust is either not possible or not required and this unused heat is lost .The ORC heat re- covery system at the Rahim Steel Plant in Bangladesh is the first of such systems will be supplied to the Steel industry. This environmentally friendly plant will recover the unused engine exhaust heat and will generate 2.630 MW of electricity on a continuous basis, displacing large amount of CO2 yearly, without interfering with the steel production process.[1] There are 8x 3.8 MW capacity gas engines at Rahim steel where a single unit’s exhaust gas flow rate 20770 kg/hr, exhaust tem- perature 479̊C. For a single unit 1578023 kcl/hr heat will recov- er from this plant. Considering whole eight units, it will turn into 12624180 kcl/hr.[1] If we will not recover the heat, the an- nual loss to be attributed to unused exhaust heat is million taka; a very significant expense for lost energy. The preferred approach to overcome this economically unsatisfactory situa- tion is to use the waste heat for the generation of electrical power. In the past some steel plant operators have installed waste heat steam boilers in their plants and have utilized the process heat to operate a steam turbine generator set. The con- ventional steam technology has some drawbacks. In particu- lar, with respect to stable steam turbine operation due to the high moisture content in the turbine exhaust and pinch point interference problems in the boiler. To overcome this draw- back, instead of using water an organic fluid will be used such as ammonia, hydrocarbons i.e. iso-pentane, iso-octane, toluene or silicon oil, etc, instead of water. ———————————————— Md.Abdullah Al Mamun is currently working in Department of R&D(project),Dana Engineers International Ltd,Dhaka,Bangladesh. For- mer student in Department of Mechanical Engineering, Khulna University of Engineering & Technology, Bangladesh. PH-+8801722211664. E-mail: mamun9131896@gmaill.com Subrato Biswas is currently working in Department of R&D(project),Dana Engineers International Ltd,Dhaka,Bangladesh. Former student in De- partment of Electrical & Electronic Engineering, Stamford Universty Bangladesh, Dhaka, Bangladesh. PH-+8801717862524. 2 HEAT RECOVERY SYSTEM FROM EXHAUST GAS, WORKING PRINCIPLE The heat contained in the exhaust gas is transferred indirectly via a thermal oil circuit or directly to the ORC plant. The ORC plant produces electricity and low temperature heat through a closed thermodynamic cycle which follows the principle of the Organic Rankine Cycle (ORC). In the ORC process, de- signed as a closed cycle, the organic working medium is pre- heated in a regenerator and in a pre heater, and then vapor- ized through heat exchanger with the hot source. The generat- ed vapor is expanded in a turbine that drives an asynchronous generator. Leaving the turbine, the organic working medium (still in the vapor phase) passes through the regenerator that is used to pre heat the organic liquid before vaporizing, there- fore, increasing the electric efficiency through internal heat recovery. The organic vapor then condenses and delivers heat to the cooling water circuit. After the condenser, the working medium is brought back to the pressure level required (for turbine operation) by the working fluid pump and then pre- heated by internal heat exchange in the regenerator. The low temperature heat is normally discharged to a thermal user or to the atmosphere. In this specific project, as per customer re- quest, we have considered to discharge the low temperature heat through an air condenser system. The following blocks diagram shows the main components of the ORC based heat recovery system E-mail: shuvorulez@gmaill.com IJSER © 2012 http://www.ijser.orgPDF Image | Waste Heat Recovery System by Using ORC
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