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3.4 Power Generation Generating power from waste heat typically involves using the waste heat from boilers to create mechanical energy that then drives an electric generator. While these power cycles are welldeveloped, new technologies are being developed that can generate electricity directly from heat, such as thermoelectric and piezoelectric generation. When considering power generation options for waste heat recovery, an important factor to keep in mind is the thermodynamic limitations on power generation at different temperatures. As discussed in Section 2, the efficiency of power generation is heavily dependent on the temperature of the waste heat source. In general, power generation from waste heat has been limited to only medium to hightemperature waste heat sources. However, advances in alternate power cycles may increase the feasibility of generation at low temperatures. While maximum efficiency at these temperatures is lower, these systems can still be economical in recovering large quantities of energy from waste heat. Table 7 summarizes different power generation technologies. Table 7 Options for Heat Recovery via Power Generation Thermal Conversion Technology Temperature Range Traditional Steam Cycle a M,H Kalina Cycle d L,M, Organic Rankine L,M Cycle c,e Thermoelectric MH Generation b Piezoelectric L generation b Thermal MH Photovoltaic Typical Sources of Waste Heat Exhaust from gas turbines, reciprocating engines, incinerators, and furnaces. Gas turbine exhaust, boiler exhaust, cement kilns Gas turbine exhaust, boiler exhaust, heated water, cement kilns Not yet demonstrated in industrial applications Not yet demonstrated in industrial applications Not yet demonstrated in industrial applications Capital Cost $1100 1,400/kWf $1100 1,500/kWf $1,500 3,500/kWf $20,000 30,0000/kWb $10,000,000/kWb N/A a. Sean Casten, 2003. Update on US Steam Turbine technology, Presented to Canadian District Energy Association 8th Annual Conference June 20th 2003. b. BCS, Inc., Engineering Scoping Study of Thermoelectric Generator Systems for Industrial Waste Heat Recovery c. Daniel Duffy, “Better Cogeneration through Chemistry: the Organic Rankine Cycle d. based on cement kiln waste heat recovery project economics. Mark Mirolli, “The Kalina Cycle for Cement Kiln Waste Heat Recovery Power Plants.” Cement Industry Technical Conference, 2005. 1520 May 2005. e. “Organic Rankine Cycle for Electricity Generation. http://www.stowaselectedtechnologies.nl f. Paul Cunningham, “Waste Heat/ Cogen Opportunities in the Cement Industry” Cogeneration and Competitive Power Journal. Vol 17, No 3 p. 3150 3.4.1 Generating Power via Mechanical Work 3.4.1.1 Steam Rankine Cycle The most frequently used system for power generation from waste heat involves using the heat to generate steam, which then drives a steam turbine. A schematic of waste heat recovery with a Rankine cycle is shown in Figure 18. The traditional steam Rankine cycle is the most efficient option for waste heat recovery from exhaust streams with temperatures above about 650700°F [340370°C]. 20 At lower waste heat temperatures, steam cycles become less costeffective, since lowpressure steam will require 25 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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