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Waste Heat Recovery Electrical Generator

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Waste Heat Recovery Solutions for Industrial Plants

• Increasing energy prices and global concerns about green house gases and CO2 emissions are driving forces toward alternative energy sources.

• Besides widely recognized alternative energy sources such as wind, solar, geothermal, and biomass, there is a huge potential in waste heat recovery.

• About 30% of the total energy consumption in US goes into industrial use.

• It is estimated that 20-50% of industrial energy consumption is released as waste heat to the atmosphere

• In some cases it is economically feasible to recover waste heat and convert into electricity.

INTRODUCTION:

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From the Department of Energy:

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Possible Industrial Waste Energy Sources

• Fuel fired furnaces (with hot combustion gases) such as Slab reheating furnaces, Cement Kilns, Glass furnaces

• Boilers and dryers• Stationary engines (such as Diesel generators)• Oil and gas pressure and reduction stations

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How does it work?

• The heat from hot waste gases are transferred to a liquid media such as water/glycol mix by means of a gas to liquid heat exchanger.

• Refrigerant liquid with lower boiling temperature is used. Waste gas temperatures are typically not hot enough to generate dry steam.

• In a second heat exchanger the hot transfer liquid boils the refrigerant.

• Refrigerant vapors feed a turbine expander in a closed loop circuit.

• Turbine is coupled with a generator producing electricity.

• This is called Organic Rankine Cycle (ORC)

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Organic Rankine Cycle (ORC) Generator

Water/LiquidHeat Exchanger

Heat Source(Water heated

by exhaust gasses)

Expander Generator

250 KW3-Phase, 460 VAC

Heated, pressurizedVapor

Condenser Heat Sink(Plant Water)

Low pressure Vapor

Low pressureLiquid

High pressureLiquid

Pump

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Patent Pending ORC generator furnace application

FURNACE STACKEXHAUST GASES

RECUPERATOR

Incoming Air/or Liquid

Outging Air/or Liquid

Stack Exhaust Gases

HEAT EXCHANGER

HEAT SOURCE TEMPERATURE AND FLOW

CONTROL

HEAT SOURCE CIRCULATING

PUMP

ORCSYSTEM

HEAT SINK CIRCUIT

GENERATOR

ELECTRICAL ENERGY

HEAT SINK MEDIA INLET TEMPERATURE SENSOR

Furnace Controller

ELECTRICAL ACTIVE POWER TRANSDUCER

STEEL MILL DISTRIBUTION

NETWORKM

VFD

PRESSURE RELIEF VALVE

PRESSURE SENSOR

PRESSURE CONTROL

VALVE

INERT GAS AT CONSTANT PRESSURE

FEEDER

CIRCUIT BREAKER

EVAPORATOR

CONDENSER

EXPANDER

PUMP

EXHAUST GASES PUMP

M

VFD

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ORC System

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ORC System Performance

• Gross Electric power: 280 kW @ 480V / 3 phase / 60 Hz• Net Electric Power: 225 to 260 kW• Ambient Temperature Operation: -22° to 122°F (-30° to

50°C)• Power Factor: Greater than 0.95 lagging• Total harmonic distortion: Less than 5%• Noise: 78 dBA at 33 ft (10m)  

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ORC System Design Attributes

• Plumbing: ASME B31.1• Turbine: Radial inflow • Generator: Induction• Heat exchangers: ASME Section VIII• Electrical Enclosure: NEMA 4 / IP65• Design life 20 years • Lubrication: Integrated internal oil lubrication• UL components: UL 1995, 984, and 174• Transient voltage/surge suppression at utility interface

IEEE C 62.41-1980 (R1995) • Utility grid-connect protective relaying function IEEE

1547 • Emissions: 0 kg/Nm3 NOx emissions (closed system)

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ORC System Description

• Working fluid R245fa (Pentafluoropropane)– Nonflammable– Nontoxic– Non-ozone depleting

• Heat source: Hot water 195° to 300°F (91° to 149°C)• Cooling requirement: Water 40° to 110°F (4° to 43°C) • Controls: PLC with Remote monitoring Web-based

gateway Operation • Designed for unattended operation • Enclosure Not required • Factory assembled Shipping Single drop flatbed truck

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Actual Data from a HSM Slab Reheat Furnace

• Furnace capacity: 320 metric ton steel / hour• Hot Waste Gas Temperature: 350C-500C

(662F-932F) after the recuperator (depending on production rate)

• Natural Gas fuel consumption 5,000 – 14,000 m3/h (176,573-494,405 cu.ft/h)

• Waste Gas release depending on production 60,000 – 160,000 m3/h (2,118,800 – 5,650,347 cu.ft/h)

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Waste Heat Recovery and Net Electricity generation potential

• 320 t/h furnace firing at max capacity 416 MMBtu/h is equivalent to 122 MW

• Energy recovery– Losses (stack) ~25 % (30 MW-h)– Potential Energy Recovery: 25% (7.6 MW-h)– Electrical Energy Recovery: 10% (760 kW-h)

• Assuming 8,000 hour per year operation:– Estimated Electrical Power: ~6,000 MW-h /year– Savings (at $0.1125/kW-h): $ 675,000/year– 5500 metric tons CO2 coal equivalent Euro zone

trade value is about $120,000/year

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Factors to consider for this Technology:

• Traditional ROI Calculations- Price of electricity- Total cost of installation- Operation and maintenance cost- Government incentives- Loan Terms, Interest Rates

• Government Mandates- Carbon credits, cap & trade- Taxes & penalties

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InstallationCost $/kW

Return on Investment (without incentives):