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ORC Combinations Some applications are already considering the use of ORC technologies with other devices in plug-and-play configurations. Namely, GE has a line of gas fueled reciprocating engines, made by GE’s Jenbacher line, for power generation. These units are starting to be paired with containerized ORC’s in order to capture exhaust gas for additional power generation. Heat Recovery Solutions, formerly part of Calnetix was bought by GE to produce the ORC’s for the GE Jenbacher gas engines (Streiter, et. al., 2010). Currently the new division has created a 125kW heat recovery generator to be used on various types of engines and biomass boilers (GE Power). Case Studies For demonstration purposes two potential sites have been analyzed. The two sites chosen are a Biopolymer Plant in Delaware and the Rutgers Cogeneration Facility in New Jersey. These represent two of the most common applications of ORCs. The biopolymer plant has enormous drying operations with lots of very low quality waste heat but continuous operation. Rutgers’ CHP facility has a waste heat source with a much higher driving temperature, but is available for bottoming cycle operations for only a few months out of the year. The Biopolymer Plant A very common industrial process is the wet formation of powders. Following any chemistry and other forming actions, a large, low temperature drying operation must take place. With upper temperatures very limited due to the nature of the biopolymers, large amounts of modestly heated air is used and then typically discarded. In the case in question this amounted to about 9.7 MMBtu/hr of air typically 140°F above the ambient. If it is assumed that the ORC heat exchangers can capture 90% of this waste heat and utilize a cycle with 10% efficiency, the electrical output would be about 250 kW. Using vendor information, both the pure cycle and infinity turbines would be good choices although the driving temperatures are still a bit low. At $1,500/kW for the device and another $1,500/kW for installation, capital costs would be $750k. At the max, the system would run 8,000 hours per year which would save $300k (assuming $0.15/kWh) per year for a two and a half year payback. Rutgers Cogeneration Facility This is a classical university type implementation with a high pressure hot water system used for space heating in the winter and in support of an absorption refrigeration cycle in the summer. For about four months out of the year little or no utilization of waste heat occurs and an opportunity exists to install a bottoming cycle using ORC technology. In this case the recoverable energy is about 30 MMBtu/hr and the working temperature of the waste heat would be about 360 °F with a 200 °F drop in temperature in the main heat exchanger. Achievable efficiencies would be about twice that for the drying case discussed above reaching, perhaps, 16%. ©2011 ACEEE Summer Study on Energy Efficiency in Industry 5-19PDF Image | Economic Implementation of the Organic Rankine Cycle in Industry
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