Coping with higher energy costs while implementing decarbonization processes has turned up the heat in the industrial sector. Industries accounts for almost 40% of total global energy use. Due to inefficiencies in their power conversion processes, around 20 to 50% of this energy becomes exhaust heat, which is unexploited and discharged into the atmosphere. This represents a valuable resource that can be channeled into clean waste heat recovery systems (also known as waste heat to power systems).
Organic Rankine Cycle (ORC) is a technology ideally suited for industrial waste heat to power application. As opposed to waste heat recovery systems based on the traditional steam Rankine cycle, ORC delivers better efficiency for lower and medium-high temperature applications (from 90°C to 400°C), as well as eliminates the requirement for water treatment and makeup.
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Exergy’s use of the innovative and pioneering Radial Outflow Turbine (ROT) in the development of waste heat to power solutions brings the advantages of ORC systems to a higher level, including:
EXERGY’s ORC single units offer a power range between 1 MW to 20 MWe.
Upon request, we can provide a turnkey solution for the whole WHR system (Intermediate circuit +ORC module).
A waste heat recovery system extracts thermal power from the exhaust gas of the industrial plant to feed the ORC module via the intermediate fluid. This fluid, usually oil, pressurized water or steam, transfers heat to the organic fluid in the ORC evaporator, where it vaporizes. The vaporized fluid then passes to the turbine.
Here, the vapor expands, causing the turbine to spin and creating electricity in the generator. The vaporized organic fluid then continues through the cycle to the condenser where once again it becomes a liquid. It then passes through the pump before beginning the cycle again.
Regardless of the heat source temperature, ORC is generally the best solution for small power output. The simplicity and compactness of the system, higher efficiency of the turbine, optimal match with the heat release curve and better operation at partial loads ensure higher system efficiency and lower specific cost compared to conventional Rankine cycles.
In certain cases, they become the only practical solution.Conversely, at considerably high temperatures and large power output, traditional Rankine cycles using steam turbines prove to be the ideal all-around solution: in these conditions, the limited increase in performance for heat sources available over 350-400°C for an ORC implies lower conversion efficiency.