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Final Report Modifications and Optimization of the Organic Rankine Cycle to Improve the Recovery of Waste Heat 1. INTRODUCTION 1.1 Project Need In the manufacturing sector, waste heat is one of the most abundant sources of energy, as it accounts for more than 2000 T Btu/year of wasted energy. Refineries, chemical processing plants, concrete plants, iron smelters, and a vast array of other industrial processes produce copious amounts of waste heat. If even a fraction of this waste heat could be economically converted to useful electricity, it would have a tangible and very positive impact on energy consumption and carbon emissions in the United States manufacturing sector. The Department of Energy (DOE) has set the goal of reducing the energy intensity of the domestic manufacturing industry by 25% over the next 10 years. The combination of several technologies will be required to meet this aggressive goal, but one of the single largest opportunities lies in the waste heat rejected from energy-intensive manufacturing processes, which exceeds 2 quadrillion Btu per year (69 GW). Current waste heat recovery technologies, including Organic Rankine Cycles (ORCs) and thermoelectrics, are technically feasible but economically unattractive; thus, limiting their current use to a small number of niche applications. Idaho National Laboratory (INL) and General Electric (GE) Global Research Center (GRC) have partnered to leverage previous research in advanced ORCs and develop a new Direct Evaporator technological solution to reduce the ORC cost up to 15%, enabling the rapid adoption of ORCs in the manufacturing sector. GE has the exceptional ability to develop and commercialize a high-quality, efficient ORC product. If within 10 years the manufacturing sector were to convert just 10% of the available waste heat into useful electricity with this technology, the manufacturing sector would save over 1 GW of electricity per year and reduce CO2 emissions by over 6,000,000 tons annually. Figure 1 provides an overview of the project. 1PDF Image | Final Report Modifications and Optimization of the Organic Rankine Cycle to Improve the Recovery of Waste Heat
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