How to utilize the waste heat generated by pretty much all the processes we engage in. An idea to convert the waste heat into useful power. A presentation give in the finals of Schenider Electric Go Green in the City Challenge -2012

1. ORC – Organic Rankine Cycle
Putting your “waste” heat to good
use
A proposal for sustainable harvesting of waste
heat

2. Waste heat
Most processes around us
generate heat
 20 to 50% of industrial energy
input is lost as waste heat
Waste heat sources
Server Room


Most heat recovery
technologies only return
useful heat (ex. Hot water)
ORC generators are a way to
convert waste heat into
electricity
Building ACs
Furnace
Factories
Restaurant Kitchens
Telecom tower
gensets
Poondla Prashant | Sindhu Maiyya

3. Organic Rankine Cycle
Generators




The working principle is similar
to that of utility power plants
which work on the Rankine
cycle
In ORCs an organic fluid
replaces the water in power
plants
Some organic fluids boil at
low temperatures
This allows ORCs to be used
with nearly any source of heat
ORC
Generator
s
Poondla Prashant | Sindhu Maiyya 20-40oC
Utility Power
Plants
o
100-500 C

4. Product offering

Modular Turbines and
Generators

Modular turbines and generators
for any amount and quality of
waste heat
Allows the system to be scaled
up easily

Low
grade
With different organic fluids ORC
can utilize low temperature heat
also

Most components of the system
are tried and tested technology
Readily available as commodity
goods
High
grade
Available as commodity goods

Poondla Prashant | Sindhu Maiyya

5. Installation and Operation
Design & Installation
HX
• Measure heat quantity and
install suitable heat exchanger
• Depending on the temperature
Organic of heat chose a working fluid
Fluid
Turbine
• Add required number of modular
turbines
• Connect turbines to generators
Gener to produce electricity
a-tor
Easy installation and maintenance
Poondla Prashant | Sindhu Maiyya

6. The Costs of ORC
But : running costs are very
low Installation Cost in USD/KW
Levelised Cost of
Gas
Electricity
Coal
in USD/MWh
Hydropower
Gas
Wind
Coal
Hydropower
Small Hydro
Wind
ORC
Small Hydro
Solar Thermal
ORC
Solar Thermal
Solar PV
Solar PV
0
0
2000
200
4000
400
The ORC system will cost an
estimated 2000-2500$/kW of
ORC is very economic over the
Poondla Prashant | Sindhu Maiyya

7. Case Study
Steel Rolling Mill of capacity 6000 tons/day ; 13 MW of
heat wasted as exhaust gases
ORC System : Capital expenditure of 4.3 M Euro
Electricity Recovered: 2.4 MW ~20% of wasted heat
Annual Production: 19,200 MWh/year
Energy Bills:
Before
After
5.6 M Eur/year
4.49 M Eur/year
Savings:
1,112,000 Euro/year ~ 18% of total bill/yr
And 25% of the investment
CO2
Emissions:
Reduction of 12,096 Tons/year
~4% of total emissions
Poondla Prashant | Sindhu Maiyya

8. Benefits of ORC waste heat
recovery


Helps recover heat that is otherwise wasted
Provides useful electricity, augmenting utility
supply
Increases efficiency of energy use
 Helps reduce energy bills




The system is modular and can be used to
harvest heat from a variety of sources over a
range of temperatures
Less manual effort: does not require fuel or any
human intervention
Poondla Prashant | Sindhu Maiyya
Relatively fast recovery on investment (~4-5

9. People Impact






Does not require any changes in
operations/daily living
Minimally intrusive: Setup in heat rejection
areas
Requires no manual operation
Helps get the maximum out of purchased
energy
Reduces CO2 emissions and lowers
environmental footprint
Not just in large scale, works for small
Poondla Prashant | Sindhu Maiyya

10. ORC Systems





Generates electricity from waste heat
Can recover up to 20% of the heat
Cost competitive with fast returns on
investment
Flexible and easy to install
Market ready technology
Way to go to make our planet energy efficient!
Especially with increasing tariffs and declining capacity.
Thank you!
Poondla Prashant | Sindhu Maiyya