Dr Vijayakumar Kunche, M.Tech., Ph.D.

ORC Technology for waste Heat

Recovery Power Generation

Waste Heat - Present situation

Industrial Processes use Oil, Gas , Coal or electricity

for Heating

Furnaces, heaters, Boilers, reformers, reactors, kilns

etc. reject 30 to 40% heat to the atmosphere through

Exhaust Flue gas.

Higher temperature exhaust gases ( >300 Deg C) are

already used in the process for pre heating, or co

generation using CHP technologies

How ever exhaust gases below 300 Deg C are not

used due to low efficiency of conventional Rankine

cycle and non availability of sustainable technology

Sources for Waste Heat Recovery

Gas Turbine Exhaust Gases 550 Deg C

Diesel generator set Exhaust Gases 450 Deg C

Cement Kiln - PH exhaust Gases 320 Deg C

Cement Kiln - Cooler Exhaust Gases 350 Deg C

Steel Reheat Furnace 400 Deg C

HRSG Exhaust Gases 140 Deg C

Boiler Exhaust Gases 180 Deg C

Oil Fired Furnaces ( petroleum &

Chemicals) 150 Deg C

Engine Jacket Cooling water 90 Deg C

Furnace heat Loss – Sankey Diagram

WHAT IS WASTE HEAT

DG set heat Loss – Sankey Diagram

Cement kiln heat Loss – Sankey Diagram

Electric Arc Furnace – Energy Balance

Why Heat Recovery

Convert Heat in the Exhaust gas to Power

ORC Power systems - Applications

STEEL

CEMENT POWER

SPONGE IRON PETROLEUM

GLASS

What IS ORC SYSTEM ?

ORC Stands for Organic Rankine Cycle.

ORC systems use Organic Fluid in place of water

In a ORC system Organic Fluid vapor will drive the

Turbine in place of Steam ( Rankine Cycle)

ORC systems can work on Low temperature Heat

resources

ORC systems are best suited for Low temperature

Heat Recovery

Organic fluids : R234fa, R 134 , Pentane, Cyclo-

pentane, n- Heptane, hexane, Toluene

ORC Power systems - FEATURES

Organic fluids have low specific consumption of

vapor in the Turbine expander

Plants work on Closed Loop control and automation

Suitable for remote monitoring and control

Very Low maintenance and operating cost

Faster supply Construction period ( maximum 6 to 9

months)

Faster Pay back period ( less than 3 years)

Potential for ORC Power systems

50 M3/ Hr Hot water available at 140 Deg C can

generate 280 Kwe Gross power

200 Tons / Hr Hot water at 90 Deg C can generate 500

Kwe power

150 Tons/ hr Hot Flue Gas at 300 Deg C can generate

1000 Kwe Gross power

Carnot Cycle – TS Diagram

Steam Cycle – TS Diagram

ORC Power systems – TS Diagram

ORC Power systems – TS Diagram

TS Diagram – Water , Organic Fluids

ORC Vs Steam Cycle

ORC – Steam Cycle Comparison

ORC Systems have Higher Conversion efficiency than

Steam Cycle for temperatures less than 350 Deg C

Steam Cycle – Schematic

ORC System – Schematic

ORC System – Schematic

Multiple ORC Units (1.25 MW) with Remote Monitoring

High Efficiency ORC systems

Low Temperature ORC systems

Furnace Waste Heat Recovery

GTG – HRSG Waste Heat Recovery

About Our Company

ESCO Company accredited by Bureau of Energy

Efficiency, Power Ministry, India

Energy Company with Global operations with

offices in Dubai, Athens, Ankara and Chicago

In house Engineering and Technology for ORC

systems

CRISIL Rated company

Having US$ 50 Million Heat recovery ORC

projects at various stages of execution

Heat Recovery power Generation – 50 Ton EAF

Hot Flue gas flow rate : 80000 NM3/Hr

Flue gas Temp before GCT : 600 Deg C

Operating Cycle : 1 Hour on 1 hour off

** Based on Earlier offer

**

Levelised Cost of Energy

Heat Pipe exchangers – Heat Recovery Boiler

33

Cement Plant Waste Heat Recovery

34

CASE STUDY

Cement Kiln PH Gross power Recovery

Net Gas flow rate 102500 NM3/Hr

Mass flow rate of Gas 132225 Kg/Hr

Gas exit temperature 305 Deg C

WHRB outlet 220 Deg C

dT 85 Deg C

Heat 2275923 kcal/Hr

Thermal 2646 KWth

ORC Gross power 635.14 Kwe

1600 TPD Cement Kiln – CASE STUDY

Clinker Cooler Exhaust Power recovery

Net Gas flow rate 112860 NM3/Hr

Mass flow rate of Gas 145589.4 Kg/Hr

Gas exit temperature 340 Deg C

WHRB outlet 220 Deg C

Heat 5483625 kcal/Hr

Thermal 6376 KWth

ORC Gross power 1530.31 Kwe

Total Gross power recovery 2165.46 Kwe

1600 TPD Cement Kiln – CASE STUDY

Gross Revenue Estimates

Gross power 2165.46 KW

Net power 1970.56 KW

PLF 0.85

Operating hrs per year 7446 Hrs/Year

Net energy generation/ year 14672821 Kwh/ yr

Average Energy Tariff 5.9 Rs./Kwh

Annual Revenue from Power 866 Rs. Lakhs/ Yr

1600 TPD Cement Kiln – CASE STUDY

Clinker Cooler WHRB

Kiln Pre Heater WHRB

Innovative Business Models

Project is Offered by FIRST ESCO through innovative

business models

BOT Model

20% investment by Mahindra Sanyo and 80% Funding by

FIRST ESCO. Monthly EMI payment by Customer. At the

end of the period Plant is handed over to the customer

PPA Model

100% Funding by FIRST ESCO, Customer signs a Power

purchase agreement. At the end of the period plant is

sold to Customer at nominal price

We invite Enquiries

End users with Waste Heat source interested in

Heat Recovery Power generation

IPP ( Independent Power producers)

Investors willing to be associated with ORC

power Projects

Energy Auditors interested in Waste Heat

Recovery projects

Mail : Info@Firstesco.in

Dr Vijayakumar : +91-9985502589

Description First ESCO

Cooling load 800 TR

Installed Qty. 1.No.

Chilled water inlet to VAM 13 Deg C

Chilled water outlet from VAM 7 Deg C

Cooling water inlet to VAM 34 Deg C

Cooling water outlet from the VAM 39.5 Deg C

Exhaust gas inlet tempt to VAM (0C) 450

Exhaust gas flow rate (kg/hr) for

VAM from glass furnace

30,660

Exhaust outlet tempt from VAM(0C) 220

Exhaust Flue Gas Heat Recovery Absorption Chiller

Glass Furnace Heat Recovery ORC

Gross and Net Power Estimates

Flue gas Flow rate (Latest operating data) 100000 Kg/Hr

Flue gas temperature ( latest Operating Data) 450 Deg C

Thermic Fludi Heater Outlet temperatures 230 Deg C

Heat Available for recovery 7162.79 KWth

Heat recovery to Thermic Fluid 5013.95 KWth

Heat input to (Turbines I &II) 3259.07 KWth

Turbine Gross output 2054.84 Kwe

Estimated auxiliary power 300 KWe

Net power to the Grid 1754.84 KWe

Revenue ( at 100000 kg/Hr Flue gas)

Gross Generation 2054 Kwe

Auxiliaries 300 Kwe

Net Power 1754 KWe

PLF 0.95

Annual generation 14596788 Kwh/Year

Energy Tariff 4.95 Rs./Kwh

Annual Revenue 72,254,101 Rs./Year

Monthly revenue 60,21,175 Rs./Month

Project Cost : Rs. 2100 Lakhs

Pay back period : 3.50 Years