ORC – Organic Rankine Cycle

Putting your “waste” heat to good use

A proposal for sustainable harvesting of waste heat

Waste heat

Server Room Building ACs

Furnace Factories

Restaurant Kitchens

Telecom tower gensets

Waste heat sources

Most processes around us generate heat 20 to 50% of industrial energy

input is lost as waste heat

Most heat recovery technologies only return useful heat (ex. Hot water)

ORC generators are a way to convert waste heat into electricity

Poondla Prashant | Sindhu Maiyya

Organic Rankine Cycle Generators

The working principle is similar to that of utility power plants which work on the Rankine cycle

In ORCs an organic fluid replaces the water in power plants

Utility Power Plants100-500oC

ORC Generators20-40oC

Some organic fluids boil at low temperatures

This allows ORCs to be used with nearly any source of heat

Poondla Prashant | Sindhu Maiyya

Product offering

Low grade

High grade

Modular Turbines and Generators

Available as commodity goods

Modular turbines and generators for any amount and quality of waste heat

Allows the system to be scaled up easily

With different organic fluids ORC can utilize low temperature heat also

Most components of the system are tried and tested technology

Readily available as commodity goods

Poondla Prashant | Sindhu Maiyya

Installation and Operation

HX

• Measure heat quantity and install suitable heat exchanger

Organic Fluid

• Depending on the temperature of heat chose a working fluid

Turbine

• Add required number of modular turbines

Genera-tor

• Connect turbines to generators to produce electricity

Design & Installation

Easy installation and maintenance Poondla Prashant | Sindhu Maiyya

But : running costs are very low

ORC is very economic over the long run!!

The Costs of ORC

Solar PV

Solar Thermal

ORC

Small Hydro

Wind

Hydropower

Coal

Gas

0 2000 4000

Installation Cost in USD/KW

The ORC system will cost an estimated 2000-2500$/kW of installed capacity

Solar PV

ORC

Wind

Coal

0 100 200 300 400

Levelised Cost of Electricity

in USD/MWh

Poondla Prashant | Sindhu Maiyya

Case Study

Steel Rolling Mill of capacity 6000 tons/day ; 13 MW of heat wasted as exhaust gases

ORC System : Capital expenditure of 4.3 M Euro

Electricity Recovered: 2.4 MW ~20% of wasted heat

Annual Production: 19,200 MWh/yearEnergy Bills:

Before After

5.6 M Eur/year 4.49 M Eur/year

Savings: 1,112,000 Euro/year ~ 18% of total bill/yrAnd 25% of the investment

CO2

Emissions: Reduction of 12,096 Tons/year ~4% of total emissions

Poondla Prashant | Sindhu Maiyya

Benefits of ORC waste heat recovery

Helps recover heat that is otherwise wasted Provides useful electricity, augmenting

utility supply Increases efficiency of energy use Helps reduce energy bills

The system is modular and can be used to harvest heat from a variety of sources over a range of temperatures

Less manual effort: does not require fuel or any human intervention

Relatively fast recovery on investment (~4-5 years)

Poondla Prashant | Sindhu Maiyya

People Impact

Does not require any changes in operations/daily living

Minimally intrusive: Setup in heat rejection areas

Requires no manual operation Helps get the maximum out of

purchased energy Reduces CO2 emissions and lowers

environmental footprint Not just in large scale, works for small

homeowners alsoPoondla Prashant | Sindhu Maiyya

ORC Systems

Generates electricity from waste heat Can recover up to 20% of the heat Cost competitive with fast returns on

investment Flexible and easy to install Market ready technology

Thank you!

Way to go to make our planet energy efficient! Especially with increasing tariffs and declining capacity.

Poondla Prashant | Sindhu Maiyya