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bulkier equipment. Moreover, lowtemperature waste heat may not provide sufficient energy to superheat the steam, which is a requirement for preventing steam condensation and erosion of the turbine blades. Therefore, lowtemperature heat recovery applications are better suited for the organic Rankine Cycle or Kalina cycle, which use fluids with lower boiling point temperatures compared to steam. TuTrubirnbeine GeGnenreartoartor CoCnodnednesnesre PuPmupmp ElEecletrcictriitcyitfyorfor plapnlatnutsuesoerofrorfor saslealteotgorgidrid WWasateste HeHaetaftrofrmom PrPorcoecsesss EvEavpaoproartoartor r Figure 18 Waste Heat Recovery with Rankine Cycle 3.4.1.2 Organic Rankine Cycle The Organic Rankine Cycle (ORC) operates similar to the steam Rankine cycle, but uses an organic working fluid instead of steam. Options include silicon oil, propane, haloalkanes (e.g., “freons”), iso pentane, isobutane, pxylene, and toluene, which have a lower boiling point and higher vapor pressure than water. This allows the Rankine cycle to operate with significantly lower waste heat temperatures— sometimes as low as 150oF [66oC]. The most appropriate temperature range for ORCs will depend on the fluid used, as fluids’ thermodynamic properties will influence the efficiency of the cycle at various temperatures. In comparison with water vapor, the fluids used in ORCs have a higher molecular mass, enabling compact designs, higher mass flow, and higher turbine efficiencies (as high as 8085%).21,22 However, since the cycle functions at lower temperatures, the overall efficiency is only around 1020%, depending on the temperature of the condenser and evaporator. While this efficiency is much lower than a hightemperature steam power plant (3040%), it is important to remember that lowtemperature cycles are inherently less efficient than hightemperature cycles. Limits on efficiency can be expressed according to Carnot efficiency—the maximum possible efficiency for a heat engine operating between two temperatures. A Carnot engine operating with a heat source at 300oF [150oC] and rejecting it at 77oF [25oC] is only about 30% efficient. In this light, an efficiency of 1020% is a substantial percentage of theoretical efficiency, especially in comparison to other lowtemperature options, such as piezoelectric generation, which are only 1% efficient. ORC technology is not particularly new; at least 30 commercial plants worldwide were employing the cycle before 1984.23 Its applications include power generation from solar, geothermal, and waste heat 26 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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