Estimation of waste heat and its recovery potential from energy-intensive industries

Saha, Bipul Krishna; Chakraborty, Basab; Dutta, Rohan

doi:10.1007/s10098-020-01919-7

Cited by 25 publications

(12 citation statements)

References 37 publications

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“…Based on the obtained results, it is confirmed that R245fa is the most cost-effective working fluid with the shortest SIPP. Finally, the results suggest that GRA with entropy information considered in this study can be employed for any possible working fluid to recover low-temperature waste heat in the ORC (Saha et al 2019) (Saha et al 2020). The results are shown in Appendix Figure . A.…”

Section: Optimal Compromise Solutionmentioning

confidence: 68%

“…In the cement industry, clinker cooling waste heat is especially suitable for power generation. Other note-worthy waste heat-producing applications include the manufacturing sectors of glass, ceramics and non-ferrous metals (Saha et al 2020) (Krishna and Basab 2016).…”

Section: A) Industrial Waste Heatmentioning

confidence: 99%

“…The Chemical Engineering Plant Cost Index (ICEPC) accounts for issues caused by inflation (Mignard 2014). The ICEPC values obtained from equipment manufacturers for the years 2001 and 2017 are 397 and 632.5 (Saha et al 2020). The final capital cost of all the equipment is obtained as:…”

Section: Economic Analysis Of the Orc And Rorc Systemmentioning

confidence: 99%

“…When the excess heat temperature exceeds 150°C, power generation from waste heat is generally economically and theoretically feasible. For Waste Heat to Power (WHP) systems, energy-intensive sectors such as steelmaking and cement are acceptable processes (Saha et al 2020). The fluctuating and intermittent existence of the waste heat source is one of the most significant technical and economic barriers which restrict the implementation of WHP (National Productivity Council 2017).…”

Section: Introductionmentioning

confidence: 99%

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Addressing Industrial Waste Heat Supply Variability With Organic Rankine Cycle Systems Incorporating Thermal Energy Storage

Saha¹,

Chakraborty²,

Dutta³

2021

Preprint

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Industrial low-grade waste heat is lost, wasted and deposited in the atmosphere and is not put to any practical use. Different technologies are available to enable waste heat recovery, which can enhance system energy efficiency and reduce total energy consumption. Power plants are energy-intensive plants with low-grade waste heat. In the case of such plants, recovery of low-grade waste heat is gaining considerable interest. However, in such plants, power generation often varies based on market demand. Such variations may adversely influence any recovery system's performance and the economy, including the Organic Rankine Cycle (ORC). ORC technologies coupled with Cryogenic Energy Storage (CES) may be used for power generation by utilizing the waste heat from such power plants. The heat of compression in a CES may be stored in thermal energy storage systems and utilized in ORC or Regenerative ORC (RORC) for power generation during the system's discharge cycle. This may compensate for the variation of the waste heat from the power plant, and thereby, the ORC system may always work under-designed capacity. This paper presents the thermo-economic analysis of such an ORC system. In the analysis, a steady-state simulation of the ORC system has been developed in a commercial process simulator after validating the results with experimental data for a typical coke-oven plant. Forty-nine different working fluids were evaluated for power generation parameters, first law efficiencies, purchase equipment cost, and fixed investment payback period to identify the best working fluid.

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Section: Optimal Compromise Solutionmentioning

confidence: 68%

Section: A) Industrial Waste Heatmentioning

confidence: 99%

Section: Economic Analysis Of the Orc And Rorc Systemmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Addressing Industrial Waste Heat Supply Variability With Organic Rankine Cycle Systems Incorporating Thermal Energy Storage

Saha¹,

Chakraborty²,

Dutta³

2021

Preprint

Self Cite

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“…With increasing environmental awareness, the sustainable use of primary resources, the introduction of renewable energy sources, improvements in the fields of energy efficiency, and lowering the dependency on fossil fuel imports are being pursued. Utilisation of low temperature and waste heat resources, especially at a temperature of approximately 100 • C and in distributed applications at industrial sites, has considerable untapped potential [1][2][3][4] and could contribute to achieving these energy goals. In the cooling sector, there is pressure to make a transition to natural refrigerants with zero ozone depletion potential and negligible global warming potential and to phase out many current ones [5].…”

Section: Introductionmentioning

confidence: 99%

Absorption Power and Cooling Combined Cycle with an Aqueous Salt Solution as a Working Fluid and a Technically Feasible Configuration

et al. 2021

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Combined systems for power production and thermally activated cooling have a high potential for improving the efficiency and utilisation of thermal systems. In this regard, various configurations have been proposed and are comprehensively reviewed. They are primarily based on absorption systems and the implementation of multiple levels of complexity and flexibility. The configuration of the absorption power and cooling combined cycle proposed herein has wide commercial applicability owing to its simplicity. The configuration of the components is not new. However, the utilisation of aqueous salt solutions, the comparison with ammonia chiller and with absorption power cycles, the focus on parameters that are important for real-life applications, and the comparison of the performances for constant heat input and waste heat recovery are novel. The proposed cycle is also compared with a system based on the organic Rankine cycle and vapour compression cycle. An investigation of its performance proves that the system is suitable for a given range of boundary conditions from a thermodynamic standpoint, as well as in terms of system complexity and technical feasibility. New possibilities with regard to added power production have the potential to improve the economics and promote the use of absorption chiller systems.

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Design and Implementation of a Control Strategy for a Dynamic Organic Rankine Cycle‐Based Power System in the Context of Industrial Waste Heat Recovery

Saha,

Chakraborty,

Mondal

et al. 2023

Energy Tech

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Transient thermal waste heat sources, such as solar energy, industrial waste heat, and ship exhaust heat, pose significant challenges in terms of their reuse in other processes. Therefore, ensuring the safe and efficient design and operation of the Organic Rankine Cycle (ORC) system for these heat sources is imperative. Comprehending the ORC system’s dynamic characteristics is necessary to formulate suitable control strategies. This paper undertakes a comprehensive review of previous studies on dynamic modelling and control of the ORC system and discusses the prevalent dynamic modelling methodologies, the challenges frequently encountered in dynamic simulations, and a range of control strategies. This paper comprehensively analyses the overall control strategies employed by ORC systems.Additionally, the energy conversion systems utilised in ORC are depicted in detail. Furthermore, using Model Predictive Control (MPC) in a simulation study allows for investigating various components’ disturbance and dynamic characteristics within the ORC system. These components include the expander, pump, condenser, and evaporator using set‐point tracking. Ultimately, this analysis aims to optimise the performance of the ORC cycle. The findings of our study indicate that the utilisation of superheating in the working fluid is the most effective method for achieving maximum power generation in an ORC system.This article is protected by copyright. All rights reserved.

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Estimation of waste heat and its recovery potential from energy-intensive industries

Cited by 25 publications

References 37 publications

Addressing Industrial Waste Heat Supply Variability With Organic Rankine Cycle Systems Incorporating Thermal Energy Storage

Addressing Industrial Waste Heat Supply Variability With Organic Rankine Cycle Systems Incorporating Thermal Energy Storage

Absorption Power and Cooling Combined Cycle with an Aqueous Salt Solution as a Working Fluid and a Technically Feasible Configuration

Design and Implementation of a Control Strategy for a Dynamic Organic Rankine Cycle‐Based Power System in the Context of Industrial Waste Heat Recovery

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