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Waste heat is supplied at a temperature of approximately 300°F (150°C) as a minimum temperature to the evaporator, and the cooling water in the condenser can be between 60°–90°F (15°–32°C). Several variations of the ORC system are offered by a number of suppliers; however, the general performance of the ORC system is within a narrow range due to thermodynamic limitations of the system. The term “efficiency” of the system is defined in many different ways and it is important to fully understand the meaning of the term “efficiency.” The efficiency represents the percentage of the supplied energy in the heating medium and recovered as electricity (converted to Btu/hr). The efficiency ranges from 8%– 15%, depending on the heating source temperature. The efficiency ranges for heat source temperature are from 300°–800°F (150°–430°C). Cost of the system varies from $2,500–$3,500 per kW design capacity. The cost distribution of a typical system is provided in Exhibit A-17. It shows that a large percentage is used for heat exchangers, and cost reduction efforts should be directed towards the development of improved—compact heat exchangers to reduce the cost as well as the footprint of the system. In the past, most of the applications of the ORC system have been in the geothermal field and non- industrial areas. Only recently are ORC systems being tested for industrial applications. Exhibit A-17: Organic Rankine Cycle (ORC) System Components and Cost Distribution Ammonia–Water System: The Kalina Cycle The Kalina cycle, which uses a mixture of 70% ammonia–30% water as the working fluid, has the potential of achieving significant efficiency gains over the conventional Rankine cycle. The general arrangement of components is very similar to the ORC system with several additional heat exchangers to improve heat recovery and enhance overall performance of the system. The system can be used for the heat source temperature range from 250°F (120°C) to as high as 1,000°F (540°C) with proper heat exchanger equipment. Operating efficiency is higher than the ORC system, about 15% with waste heat temperature in the range of 300°F (150°C), which improves at higher heat source temperature. The main reason for the improvement in efficiency is that the boiling of the ammonia–water mixture occurs over a range of temperatures, unlike other fluids; therefore, the amount of energy recovered from the gas stream is much higher. The condensation of ammonia–water alsooccurs over a range of temperatures, permitting additional heat recovery in the condensation system, unlike Rankine cycle, where the low-end Other cost 25% Power distribution 15% Heat excahngers 30% Cooling water system 15% Turbine - Generator 15% Water/condensate Industrial Waste Heat Recovery Page 61PDF Image | Industrial Waste Heat Recovery: Potential
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