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3974 B.F. Tchanche et al. / Renewable and Sustainable Energy Reviews 15 (2011) 3963–3979 Table 6 Short list of ORC waste heat recovery plants. Location Mirom Roeselare, (Belgium), owner: Spie Belgium SA Oxon Italia SPA, Pavia (I), Italy RHI, Radenthein (A), Austria Italcementi, Ait Baha (MA), Italy Gasseltenijveenschemond, Netherlands Nieuweroord, Netherlands National Swimmingcentra The Tongelreep, Eindhoven, Netherlands Savona, BC, Canada Kalamazoo Valley Community College, Michigan, USA TransCanada pipeline, Gold Creek, Alberta, Canada Northern Border Pipeline, St. Anthony, North Dakota Northern Border Pipeline, Wetonka, South Dakota Alliance Pipeline, Kerrobert, Saskatchenwan, Canada Northern Border Pipeline, Garvin, Minnesota Northern Border Pipeline, CS 13, Minnesota Kern River Pipeline, Goodsprings, Nevada Spectra Pipeline, Australian, BC, Canada Waste heat generating system Waste incinerator plant 8.3 MW MAN diesel engine magnesite production process Cement production process 2 × 646 kWe Jenbacher biogas engines 2 × 835 kW Jenbacher biogas engines 2.1 MW ABC Bio-oil engine Simple cycle gas turbine plant (18.5 MW) Boiler Gas Turbine (Rolls Royce, RB211/38000 HP) Gas Turbine (Rolls Royce, RB211/38000 HP) Gas Turbine (Rolls Royce, RB211/38000 HP) Gas Turbine (GE LM2500/33000 hp) Gas Turbine (Rolls Royce, RB211/38000 HP) Gas Turbine (Rolls Royce, RB211/38000 HP) Gas Turbine (3 × Solar Mars 100/15000 HP) Gas Turbine (GE PGT25+/31000 hp) Heat source type Hot water at 180 ◦ C Exhaust gases Hot exhaust gas Kiln exhaust gas Exhaust Exhaust Exhaust Exhaust exhaust Exhaust Exhaust Exhaust Exhaust Exhaust Exhaust Exhaust Exhaust Capacity 3MW 0.5 MW 0.8 MW 2MW 125 kW 150 kW 150 kW 4.5 MW 6.5 MW 5.5 MW 5.5 MW 5.5 MW 5.5 MW 5.5 MW 6MW 5MW Technology Start up Refrigerant/turboden 2008 Siloxane/turboden 2008 Siloxane/turboden 2009 Siloxane/turboden 2009 ORC/tri-o-gen ORC/tri-o-gen ORC/tri-o-gen Pentane 2008 Twin-screw 2010 expander/Electratherm Ormat technology 1999 Ormat technology 2006 Ormat technology 2007 Ormat technology 2008 Ormat technology 2009 Ormat technology 2010 Ormat technology 2010 Ormat technology 2010 [129], automotive industry [130,131], maritime transportations [132], etc. Three prospective areas are analyzed here below: the cement industry, the automotive industry, and the shipping indus- try. Cement manufacturing process is very energy-intensive – the energy required for the production of a ton of cement is between 3 and 5 GJ/ton [133]. Fuelled by the economic growth experienced in developing countries, the cement production is steadily increas- ing. China alone produced about 1388 million metric tons (Mt) in 2008, which accounts for nearly half of the world’s total cement production [134]. Cement manufacturing process is well known [133–135] and critical step is the clinker production that consumes about 80% of the total energy. Clinker is produced by burning a mixture of materials, mainly limestone, silicon oxides, aluminum, and iron oxides. The exit gases from the kilns are exhausted to the atmosphere at around 300–350 ◦ C in 4 stages preheater and at 200–300 ◦ C in case of 5–6 stages preheater. The clinker coming out of the kiln is at around 1000 ◦ C and is cooled to 100–120 ◦ C using ambient air. This generates hot air of about 200–300 ◦ C. Hot air and gases exhausted to the environment can be recovered using well proven waste heat recovery steam technology pioneered by Japanese or by adopting low-temperature organic Rankine cycles [121]. Engin and Ari [136] conducted an energy audit of a typical cement factory with a capacity of 600 tons/day and showed that 40% of the total input energy was being lost through hot flue gas (19.15%), cooler stack (5.61%) and kiln shell (15.11%). By using a waste heat recovery steam cycle, low temperature heat from both hot air and flue gas streams could be recovered to produce on-site power of about 1 MW at a cost effective rate with a payback period of 17 months. Depending on the size of the plant, up to few tens of MW can be generated to cover 10–20% of the electricity needs and several plants have been installed worldwide, mainly in Japan, China and India. Organic Rankine cycles that offer greater modu- larity, lower investment and maintenance costs over steam cycles, could be a technology of choice for energy efficiency in cement industry. In the 1970s and 1980s during the oil crisis, car manufacturers were concerned about reducing fuel consumption. But just after the oil shocks, the idea was left aside. However, in recent years, with new regulations on greenhouse gas emissions entering into force, the interest of reducing the fuel consumption and CO2 emis- sions in cars is renewed. In current cars, the combustion engine onboard requires a supply of fuel three times as great as the power actually generated. This is because the combustion engine with its maximum efficiency of about 40% converts less than one third of the energy it receives into mechanical power [137]. For illustration, the heat balance of a typical 1.4 liters spark ignition engine has a thermal efficiency ranging from 15 to 32% depending on operating conditions. The remaining 60–70% of the energy input is rejected to the environment through the radiator (18–42%) and the exhaust system (22–46%) [130]. Rankine cycles are regarded as promising solution to recover this heat lost for thermal comfort or power gen- eration. Several encouraging trials have been reported with steam as working fluid. Honda [131] designed and tested a prototype. The thermal efficiency of the latter improved from 28.9% to 32.7% when tested at a constant speed of 100km/h. Organic Rankine cycles could provide substantial fuel saving by recovering not only the heat from exhausts but also that of the cooling circuit. Several paths are under investigation in view of improving fuel efficiency in ships; the waste heat recovery being part of the R&D [138]. A conventional diesel engine converts about 30–50% of the energy of the bunker fuel into mechanical work for the ship’s propulsion system and the remaining part is lost in the form of waste heat through the cooling system and the exhaust. Rankine cycles could recover part of the heat exhausted and turn it into additional power for onboard services, and/or to supplement the propeller. However, research papers on waste heat recovery on ships are scarce in literature. This could be explained by the lit-PDF Image | Renewable and Sustainable Energy Reviews 15
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