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The new configuration allowed complete isolation of ORC units from the existing system. This protective measure insulated the plant’s steel production from any possible problems in the waste heat recovery system. Four ORC units were installed in parallel, drawing hot water from the hot water collector. Also in parallel with the ORC units are four bypass valves: two pneumatically actuated bypass valves, one automatic pressure relief valve, and one manual bypass valve. One of the pneumatic valves is used in normal operation while the other one is standby for backup. These air operated valves are controlled by the PLC to regulate the pressure difference between the new hot water furnace exit collector and the ORC exit collector to ensure that sufficient hot water flow is maintained to the units independent of the number of units in operation. The automatic pressure relief safety valve ensures that the differential pressure across the ORC units does not exceed the design limit. The manual bypass valve is set partially open to allow some water flow as an additional precaution in case of failure of other valves. Cooling water for the ORC units is provided by the existing clean plant cooling water circuit. Figure 6. Simplified Evaporative Cooling System with ORC Units The ORCs are connected to a low voltage (400 V, 50 Hz) furnace area busbar. A simplified one line power diagram is shown in Figure 7. Each ORC unit is equipped with a main disconnect switch and dedicated circuit breakers for each component. During the initial start of operation, the 280 kW induction generator starts as a motor turning the turbine. The generator is first energized with a soft starter in order to limit the starting current. Once the generator is running at full speed the soft starter is bypassed by a contactor directly connecting the generator with the AC busbar. When the turbine starts driving the generator above synchronous speed, the system begins to inject active power into the busbar. A filter and a power factor correction unit keep the overall power factor at approximately 0.95. They also filter the harmonics injected by the refrigerant pump’s AC inverter. The induction generator does not require any type of synchronization.PDF Image | Novel Application of Organic Rankine Cycle (ORC) Technology for Waste Heat Recovery from Reheat Furnace Evaporative Cooling System
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