ORC Technology for waste Heat Recovery Power Generation

ORC Technology for waste Heat Recovery Power Generation First ESCO India Pvt. Ltd.

Barriers to Waste Heat Recovery ØTechnological Barriers ØFinancial Barriers ØRisk-Reward imbalance

Waste Heat – Technological barriers ØTechnology is available for high temperature recovery using conventional HRSG ( heat recovery steam generators) and Steam turbine Generators using Rankine cycle Ø Rankine cycle is not suitable for Low temperature heat recovery

Waste Heat – Financial barriers ØORC technology for Low grade heat recovery is available in Europe and other parts of the world. But the systems are Too expensive to adapt Ø Pay back period is too long ØEconomically not feasible due to the subisidised electricity tariffs

Waste Heat – Risk reward Imbalance ØAny new technology, users would initially perceive high risk Ø If the economic benefit due to the technology is not sustainable due to High Capital expenditure, there is no motivation to take the RISK

Waste Heat - Present situation ØIndustrial Processes use Oil, Gas , Coal or electricity for Heating ØFurnaces, heaters, Boilers, reformers, reactors, kilns etc. reject 30 to 40% heat to the atmosphere through Exhaust Flue gas. ØHigher temperature exhaust gases ( >300 Deg C) are already used in the process for pre heating, or co generation using CHP technologies ØHow 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) Engine Jacket Cooling water 150 Deg C 90 Deg C

Furnace heat Loss – Sankey Diagram

DG set heat Loss – Sankey Diagram WHAT IS WASTE HEAT

Cement kiln heat Loss – Sankey Diagram

Electric Arc Furnace – Energy Balance

Why Heat Recovery HEAT = MONEY Convert Heat in the Exhaust gas to Power

ORC Power systems - Applications CEMENT STEEL POWER SPONGE IRON GLASS PETROLEUM

What IS ORC SYSTEM ? ØORC Stands for Organic Rankine Cycle. Ø ORC systems use Organic Fluid in place of water ØIn a ORC system Organic Fluid vapor will drive the Turbine in place of Steam ( Rankine Cycle) ØORC systems can work on Low temperature Heat resources ØORC systems are best suited for Low temperature Heat Recovery Organic fluids : R 234 fa, R 134 , Pentane, Cyclopentane, n- Heptane, hexane, Toluene

Organic fluids for ORC

ORC Power systems - FEATURES Ø Organic fluids have low specific consumption of vapor in the Turbine expander ØPlants work on Closed Loop control and automation ØSuitable for remote monitoring and control ØVery Low maintenance and operating cost ØVery stable and SAFE to operate, Provided with automatic flame detection and CO 2 flooding system ØFaster supply Construction period ( maximum 6 to 9 months) ØFaster Pay back period ( less than 3 years)

ORC –Safety considerations Ø Gas detectors Ø Flame detectors Ø Automated Foam dispensers Ø Automated CO 2 Fire extinguishing systems Ø CCOE Approval

ORC SYSTEMS - AVAILABILITY ØHigh Temperature ORC systems Temperature Range Power range ORC Fluids Ssystem efficiency : 70 Deg C to 170 Deg C : 10 KW to 1000 KW : R 245 Fa, R 134, 3 M Fluids : up to 14% Ø Low Temperature ORC systems Temperature Range Power range ORC Fluids System efficiency : 170 Deg C 70 300 Deg C : 250 KW to 10 MW : Cyclo pentane, hexane, n-heptane, Tolune : up to 25%

Potential for ORC Power systems Ø 50 M 3/ Hr Hot water available at 140 Deg C can generate 280 Kwe Gross power Ø 200 Tons / Hr Hot water at 90 Deg C can generate 500 Kwe power Ø 150 Tons/ hr Hot Flue Gas at 300 Deg C can generate 1000 Kwe Gross power

Carnot Cycle – TS Diagram

Steam Cycle – Schematic

Steam Cycle – TS Diagram

ORC Power systems – TS Diagram

ORC Power systems – TS Diagram

TS Diagram – Water , Organic Fluids

ORC Vs Steam Cycle

Steam Cycle – Model Simulation

ORC – Model Simulation

ORC – Steam Cycle Comparison ORC Systems have Higher Conversion efficiency than Steam Cycle for temperatures less than 350 Deg C

ORC System – Schematic

ORC System – Schematic

FIRST ESCO High Efficiency ORC systems Parameter Hot oil flow rate Hot oil inlet temperature Hot oil outlet temperature Thermal input to ORC Cooling water inlet temperature Cooling water Outlet temperature Gross Power output Net Power output Units kg/Hr Deg C MWth Deg C Kwe FE-500 FE-1000 FE-2000 FE-3000 FE-5000 34000 68000 136000 204000 340000 280 280 280 180 180 180 2. 17 4. 35 8. 70 13. 05 21. 74 39 39 39 29 29 29 500 1000 2000 3001 5001 450 900 1800 2701 4501

FIRST ESCO Low Temperature ORC systems

Multiple ORC Units (2. 5 MW) with Remote Monitoring

2 MW ORC Units (2. 5 MW) with Remote Monitoring

Furnace Waste Heat Recovery

GTG – HRSG Waste Heat Recovery

Heat Recovery power Generation – 50 Ton EAF Ø Hot Flue gas flow rate : 80000 NM 3/Hr ØFlue gas Temp before GCT : 600 Deg C ØOperating Cycle : 1 Hour on 1 hour off

Heat Pipe exchangers – Heat Recovery Boiler 39

Clinker Cooler WHRB

Kiln Pre Heater WHRB

Innovative Business Models Project is Offered by FIRST ESCO through innovative business models ØBOT 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 ØPPA 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 Ø End users with Waste Heat source interested in Heat Recovery Power generation ØIPP ( Independent Power producers) ØInvestors willing to be associated with ORC power Projects ØEnergy Auditors interested in Waste Heat Recovery projects Mail : Info@Firstesco. in Dr Vijayakumar : +91 -9985502589

About Our Company ØESCO Company accredited by Bureau of Energy Efficiency, Power Ministry, India ØEnergy Company with Global operations with offices in Dubai, Athens, Ankara and Chicago ØIn house Engineering and Technology for ORC systems ØCRISIL Rated company ØHaving US$ 50 Million Heat recovery ORC projects at various stages of execution

First ESCO India Pvt. Ltd. 16, Prince Apartments Chinna Waltair VISHAKAPATNAM, pin 530017, INDIA www. Firstesco. in Mobile : 91 -9985502589 Email: info@Firstesco. in