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Modifications and Optimization of the Organic Rankine Cycle Improving Recovery of Waste Heat in Industrial Processes This project developed and demonstrated a direct evapora- tor for an Organic Rankine Cycle (ORC) system that utilizes waste heat from a reciprocating engine or gas turbine. Introduction Waste heat from turbines and engines used in industrial ap- plications along with waste heat from industrial processes are exceptionally abundant sources of energy. 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 the economic health, energy consumption, and carbon emis- sions in the U.S. manufacturing sector. The current waste heat recovery technologies, including ORC systems and thermoelec- trics, are technically feasible but in many cases economically unattractive. This limits their current use to a small number of niche applications. ORC technologies operate by transferring heat from the source through an evaporator to boil a fluid and create vapor that is expanded across a turbine or other work extraction device. This creates shaft power that can be easily turned into electrical power through a generator. Current limitations in ORC technolo- gies have led to inefficient systems that offer only marginal economic benefits. These limitations stem from the use of a secondary heat transfer loop in most commercial systems to offset safety risks. This secondary loop creates additional costs for each unit, increases the opportunity for component failure, and reduces the conversion efficiency of the system. To address these problems, researchers are working to develop advanced and cost-effective ORC systems. In this project, the research team leveraged previous work in advanced ORC tech- nologies to develop a new direct evaporator solution that will reduce the ORC system cost by up to 15%, enabling more rapid adoption of the technology for industrial engines and turbines. Benefits for Our Industry and Our Nation GE has more than 1,800 simple cycle gas turbines installed in North America and Europe that cumulatively generate more than 60 GW of electrical power. If 20% of this installed base were ret- rofitted with the proposed ORC technology, 3 GW of additional electrical power could be produced, which would effectively utilize 90 trillion Btu of waste heat per year. These energy sav- ings represent CO2 emission savings of 4.8 million metric tons, and economic savings of $630 million. An anticipated additional economic benefit of this research effort is a reduction in the costs of ORC technology, which will provide greater returns on invest- ment than previous ORC systems. Applications in Our Nation’s Industry This technology will be initially retrofitted for waste heat recov- ery in reciprocating engines and gas turbines. ORC systems can be used in waste heat recovery applications for a broad range of industries, including metals and minerals manufacturing, refiner- ies, chemical processing plants, concrete plants, iron smelters, and an array of other industrial processes. Project Description This project optimized the ORC for the conversion of low- temperature waste heat from gas turbine or reciprocating engine exhaust to electricity. The work entailed detailed design and modeling of a direct evaporator concept that improves efficiency by eliminating the usual secondary heat exchanger loop. Thermal decomposition and flammability analyses of the organic work- ing fluid were performed to maximize system performance and minimize safety risks. A prototype test facility was designed and constructed to evaluate the operation of the direct evaporator. The result of these efforts was a safe, economically feasible direct evaporator design to be manufactured with the gas turbine or reciprocating engine as a single package that is easy for customers to install and operate. The direct evaporator and supporting equipment installed at the GE test facility. Photo courtesy of Idaho National Laboratory.PDF Image | Improving Recovery of Waste Heat in Industrial Processes
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