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removing the contaminants often removes the heat at the same time. Other waste heat sources are difficult to recover because of equipment configuration or operational issues. Applicable Technologies Steam Rankine Cycle (SRC) – The most commonly used system for power generation from waste heat involves using the heat to generate steam in a waste heat boiler, which then drives a steam turbine. Steam turbines are one of the oldest and most versatile prime mover technologies. Heat recovery boiler/steam turbine systems operate thermodynamically as a Rankine Cycle, as shown in Figure 2. In the steam Rankine cycle, the working fluid— water—is first pumped to elevated pressure before entering a heat recovery boiler. The pressurized water is vaporized by the hot exhaust and then expanded to lower temperature and pressure in a turbine, generating mechanical power that can drive an electric generator. The low-pressure steam is then exhausted to a condenser at vacuum conditions, where heat is removed by condensing the vapor back into a liquid. The condensate from the condenser is then returned to the pump and the cycle continues. Organic Rankine Cycles (ORC) – Other working fluids, with better efficiencies at lower heat source temperatures, are used in ORC heat engines. ORCs use an organic working fluid that has a lower boiling point, higher vapor pressure, higher molecular mass, and higher mass flow compared to water. Together, these features enable higher turbine efficiencies than in an SRC. ORC systems can be utilized for waste heat sources as low as 300 oF, whereas steam systems are limited to heat sources greater than 500 oF. ORCs have commonly been used to generate power in geothermal power plants, and more recently, in pipeline compressor heat recovery applications. The Kalina Cycle is another Rankine cycle, using a mixture of water and ammonia as the working fluid, which allows for a more efficient energy extraction from the heat source. The Kalina cycle has an operating temperature range that can accept waste heat at temperatures of 200 oF to 1,000 oF and is 15 to 25 percent more efficient than ORCs at the same temperature level. Kalina cycle systems are becoming increasingly popular overseas in geothermal power plants, where the hot fluid is very often below 300 oF.11 The three types of Rankine power cycles discussed above overlap to a certain degree. There are advantages to each, however: • SRCs are the most familiar to industry and are generally economically preferable where the source heat temperature exceeds 800 oF. 11 A Rankine cycle operating with a liquid waste heat source can be designed around lower temperatures than for one based on a gaseous heat source, such as industrial process flue gases. The minimum liquid waste temperature for economically feasible operation is 200 oF. Figure 2: Rankine Cycle Heat Engine 3PDF Image | waste heat to power systems
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