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Water is being circulated through the system at a rate of 161 kg/sec, and the supply and return water temperatures are around 127°C and 142° C, respectively. Using standard tables for the internal energy of water, it can be determined that energy is being added to the system at a rate of 10,319 kJ/sec, or 10,319 kW. ∆t Equation 1 At full capacity it was estimated that a standard ORC unit would require about 3196 kJ/sec of thermal energy to produce 250 kW net electrical power. Based on the result of Equation 1, it was estimated that there was enough excess heat to supply 3 ORC units. Other heat calculation methods such as using the amount of make-up water consumption, pointed to less heat availability, just enough to feed 2 ORC units. At the end, Tosçelik decided to install 4 x 250 kW ORC units thinking about future expansion such as applying waste heat recovery to exhaust flue gases in the event there is unused excess capacity. New Equipment Installation Steel production is Tosçelik’s core business; therefore it was very important to introduce the new ORC units into the existing system with minimum interruption in Hot Strip Mill plant operations. Since the ORC efficiency improves with the increased resource temperature, Tosçelik and TMEIC decided to insert the ORC units into the return line from furnace skids to the drum, where water heated by the furnace is returning to the drum. To equalize the inlet water temperature across each ORC unit, Tosçelik installed a new hot water collector and combined the output of the cooling water flow from each skid at the exit of the furnace. Downstream of the ORC units, a new ORC exit collector was installed to recombine the water from each stream so that water of a uniform temperature re-enters the drum. A simplified diagram of the evaporative cooling system after the addition of the ORC units can be seen in Figure 6. Figure 4. ORC Unit Figure 5. ORC Hot Water Inlet and Cooling Water Piping Installation of these two new collectors was performed during a previously scheduled yearly maintenance shutdown, before any ORC unit was delivered to the site. A manual bypass valve was installed between these new collectors allowing continuity of flow. There were also isolation valves attached to these collectors in preparation for the new ORC units, which would allow connection and commissioning of ORCs without needing another furnace shutdown in the future. ∆UU−UdU• dU kg kJ = 2 1 → =m∗(u2 −u1)→ =161 ∗(u142oC −u127oC)=10,319 ∆t dt dt sec secPDF Image | Novel Application of Organic Rankine Cycle (ORC) Technology for Waste Heat Recovery from Reheat Furnace Evaporative Cooling System
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