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All of the critical system parameters were archived in a data collection system that is capable of storing information for several months. Calculation of power set point for ORC units is represented by the block diagram in Figure 10. The control loop continuously monitors the heat extracted by the ORCs and the available excess heat in the system. Since the hot resource flow for each ORC was not known, a simple look-up table was constructed using ORC datasheet values. This lookup table is shown in Table I. Based on the actual gross power of ORC units, the lookup table is used to estimate the heat consumed. Once the actual heat consumption and the available heat are known, the new heat extraction value is then calculated and using the same lookup table, converted back to the new gross power reference for ORC units. Reference – T4 fbk – Error – Total Flow – Eqn - Figure 10. ORC power set point calculation block diagram HMI screen input value for the desired drum temperature This represents the actual drum temperature measured at the main circulation pump outlet Difference between desired and actual drum temperature Total flow feedback measured after the circulation pump (summation of all ORC units and bypass flow) H = where H = Cp = Mass = ∆T = Cp *Mass*∆T Equation2 Heat Flow (kJ/sec) Thermal capacity of water = 4.25 kJ/kg ̊C at 125C and 0.5MPa Total flow in (kg/sec) T1-T2 temperature error from the proportional gain regulator (C) The Heat Flow for each gross kW power set-point for one ORC unit has been added to Table I, by using the Equation 2 above where T1 = 142C stands for ORC resource inlet temperature and T2 is for the ORC outlet temperaturePDF Image | Novel Application of Organic Rankine Cycle (ORC) Technology for Waste Heat Recovery from Reheat Furnace Evaporative Cooling System
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