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that explored the option of replacing their steam condenser. By eliminating their facility’s cooling tower, they were able to reroute that waste heat into an organic Rankine cycle, generating 294 kW of electricity. This resulted in a cost savings of $309,052; with electricity costs at $0.12 the payback period was 4.2 years. Use for Recovery of Low Grade Waste Heat It is believed that the organic Rankine cycle is most useful when applied to the recovery and use of waste heat. Two major applications are in Combined Heat and Power plants using biomass as fuel, and process waste heat applications. System sizing varies greatly, ranging from 10 kW units to as large as several megawatt units. Regardless of system size, the real importance of the organic Rankine cycle is that the system can convert low grade waste heat to power. Working examples or industrial waste heat recovery systems have been in place at several cement kilns and compressor stations since 1999 (Energy Services, Oct 2009). Whereas using the steam cycle to recover energy off low grade heat streams would be very expensive, using the organic Rankine cycle would make the process economically feasible and worthwhile. In fact, organic Rankine cycle engines are capable of effectively operating at temperatures as low as 158°F (Duffy, 2005). There is limited concern with the organic Rankine cycle competing with heat pumps, as heat pumps are limited in their maximum operating temperatures, roughly 200°F (Energy Services, Oct 2009). Working Fluids Selection Given that the ORC relies on a refrigerant as its working fluid, there is quite a selection to choose from and several important factors to take into consideration when choosing. Two main considerations must be taken into account: 1) its effect on cycle efficiency/cost and 2) its impact on the environment. The range of temperatures seen by an ORC system governs the type of working fluid that can be used. The chemical composition of refrigerants begin to break down at high temperatures and thus they must be chosen so that it remains stable at the system’s highest temperature but have a freezing point well below the lowest temperature in the cycle. The fluid must have a high heat of vaporization and density to efficiently extract as much energy from the waste stream, as thermodynamically allowable. In addition, operating temperatures must be kept sufficiently low to keep equipment and personnel cost to a minimum. As for the environmental aspect, it should have a low ozone depleting potential as well as a low greenhouse warming potential. Non-corrosive, non-flammable, non-toxic and affordable are other important characteristics to look for when choosing a suitable working fluid (Quoilin, May 2007). Economic Considerations As with most capital purchases, getting usable cost data for these types of devices and installations can be very difficult. Several case studies exist (including recently Bourji, et. al, 2010) but in almost all of these cases the data is presented in aggregate format with little in the way of direct costs. In general, primary mover costs are doubled to estimate total implementation costs. Paybacks or ROI estimates improve when the cost of the purchased electricity which it is replacing is increased. Best case scenarios are for a four-year payback (ROI = 25%). ©2011 ACEEE Summer Study on Energy Efficiency in Industry 5-15PDF Image | Economic Implementation of the Organic Rankine Cycle in Industry
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