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BACKGROUND The Rankine Cycle is a well known and understood thermodynamic cycle used to convert heat into work, most commonly applied in power generation. In the conventional Rankine Cycle, the working fluid (usually water) is heated to saturation in a boiler, expands through a turbine while producing work, returns to the liquid state in a condenser, and is pumped back into the boiler to repeat the cycle. The ORC differs from the traditional Rankine Cycle because instead of water, a high molecular mass organic fluid is used as the working fluid. This organic fluid is typically characterized by a lower boiling point than that of water, enabling the ORC to operate at lower temperatures and take advantage of waste heat generated at lower temperatures than other recovery methods (Figure 3) Heat Source High pressure Liquid Pump Low pressure Vapor Plant Water Low pressure Liquid Water/Liquid Heat Exchanger Heated, Pressurized Vapor Turbine Expander Generator Power Output Condenser Figure 3. Physical Layout of Rankine Cycle Power Generation Equipment UPGRADE OVERVIEW Evaporative Cooling System The evaporative cooling system installed to cool the furnace skids of the Tosçelik HSM walking beam furnaces is a semi-closed loop system. Cooling water at a pressure of around 0.27 MPa (39 psi) is maintained in a drum where it exists as mixture of water and saturated steam. Water is circulated from the drum through the fixed and movable walking beam skids by main circulation pumps. The excess heat transferred from the skids to the cooling water increases the energy of the cooling water system and would cause an increase in system pressure, but a constant system pressure is maintained by continuously venting steam from the drum. As steam is vented, makeup water is added to maintain a constant volume of water in the system. Calculations To select the correct waste heat recovery equipment for this project, it was necessary to understand the amount of waste heat that was available. Several methods were used to calculate the waste heat potential, with each method relying on a basic energy balance. One calculation method to determine the amount of waste heat that would be available for recovery without adversely affecting the system performance would be to calculate the energy added to the water from the furnace and size the equipment to remove that amount of energy. The difference in the internal energy of the system can be shown as: ∆U = U2 – U1 , or on a continuous basis: where U is total energy content, is mass flow and u is energy content per unit mass.PDF Image | Novel Application of Organic Rankine Cycle (ORC) Technology for Waste Heat Recovery from Reheat Furnace Evaporative Cooling System
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