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*Corresponding author: a.m.c.auld@durham.ac.uk Alison Auld, Arganthae ̈l Berson and Simon Hogg* School of Engineering and Computing Sciences, Durham University, Durham DH1 3LE, UK ............................................................................................................................................. Abstract A theoretical study of organic Rankine cycles (ORCs) powered by three different waste heat sources is presented. The heat sources, all found in industrial processes, span a range of energy scales capable of powering ORCs from 10 kW to 10 MW. A novel method of pinch point analysis is presented, allowing variable heat input to the ORC. This study models the ORC over a range of operating conditions and with different working fluids for each heat source. Results from each source are compared to assess the influence of different heat source characteristics on optimal ORC design. Keywords: organic Rankine cycles; waste heat recovery Received 25 January 2013; revised 10 April 2013; accepted 11 April 2013 Organic Rankine cycles in waste heat recovery: a comparative study .............................................................................................................................................................. ................................................................................................................................................................................ 1 INTRODUCTION Waste heat is an inherent and abundant byproduct of many in- dustrial processes. Often, industrial waste heat is too low in tem- perature for any useful energy to be extracted from it by conventional cycles (e.g. steam turbines). Organic Rankine cycles (ORCs) rely on the same principle as conventional steam/ water Rankine cycles used for primary thermal power generation purposes. ORCs use organic working fluids. These fluids have lower boiling points than steam/water at the same pressure, which allow them to be driven by low-grade waste heat. ORCs functioning down to 73:38C have been reported [1]. By convert- ing waste heat into mechanical power, ORCs can improve the ef- ficiency of a wide range of thermal cycles. Several studies model ORC cycles theoretically [1 – 5]. Roy et al. [2] investigate the optimal ORC configuration and working fluid for an ORC system powered by waste flue gas from a 420 MW power station. However, the optimization is con- strained by using a constant heat supply. This approach may be appropriate for flue gas, as there is a limit to the cooling of flue gas to prevent corrosion of components. It may not be appropri- ate to extend this model to other applications where there is no lower limit on the source heat temperature. Other studies use commercial software to model ORCs [3, 4]. Aneke et al. [3] use IPSEpro to simulate the ORC cycle of the Chena plant. This model requires the work output to be specified as well as source and sink heat conditions. Similarly, Little et al. [4] model various cycles with a constant heat input using the software package EES. In this study, we aim to optimize the work output from the cycle, so an alternative modelling strategy is used in order to understand the effect of changing heat input into the cycle. Katsonos et al. [5] model an ORC with heat supplied by exhaust gas of a diesel engine. Heat input to the ORC is variable because it is modelled as a function of available heat supply, pinch point temperature difference and heat exchanger (HEx) size. This approach means that the potential improvement in brake-specific fuel consumption of an engine is modelled within practical boundaries. A similar modelling strategy is adopted in this study. Tchanche et al. [6] present a review of ORCs by application. The technical differences of ORC systems and the maturity of existing ORCs are assessed for each application. While this ap- proach gives a thorough understanding of each case, it is not clear whether a generalized approach to optimal ORC design is possible. Similarly, organic cycles using a range of working fluids are reviewed by Chen et al. [7]. Fluids are grouped according to how dry or wet they are and an effort is made to determine the most appropriate cycle configuration for each group. However, as is acknowledged in this study, cycle configuration is strongly dependent on the temperature profile of the heat source, and no general principles were drawn from the analysis. In the present study, Matlab and FluidProp [8] have been used to build an ORC model capable of simulating different organic fluids over a wide range of operating conditions for any heat source and sink. The model requires input conditions for both the heat source and sink and a pinch point temperature dif- ference for the heat exchange processes into and out of the cycle. An advantage of the model is that the heat input is not fixed, as it is in some other studies, e.g. [2], but determined by pinch point analysis. This means that the maximum heat input to the International Journal of Low-Carbon Technologies 2013, 8, i9–i18 # The Author 2013. Published by Oxford University Press. All rights reserved. For Permissions, please email: journals.permissions@oup.com doi:10.1093/ijlct/ctt033 i9 Downloaded from https://academic.oup.com/ijlct/article/8/suppl_1/i9/771990 by guest on 13 January 2021PDF Image | Organic Rankine cycles in waste heat recovery
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