Innovative Technologies for Waste Heat

Recovery Power Generation

Dr Vijayakumar Kunche, M.Tech., Ph.D.

What is Waste Heat

Types of waste Heat in Industries

Hot exhaust gases from Chimney / stack

Surplus steam
Hot metal
Hot oil
What is Waste Heat
Furnace heat Loss – Sankey Diagram
What is Waste Heat
DG set heat Loss – Sankey Diagram
What is Waste Heat
Cement kiln heat Loss – Sankey Diagram
Why Waste Heat Recovery

Waste exhaust gas = ENERGY RESOURCE

 By recovering waste heat Furnace / boiler/
power plant efficiency can be increased
Save valuable Oil / Coal/ Gas
Generate Extra power with out additional
Fuel
Improve bottom line by reducing
operational costs
What is Waste Heat Recovery
Power generation

 Capturing Heat From the Hot Exhaust gases

to a Thermic Fluid

Converting Heat energy in the thermic Fluid to

POWER using ORC turbine Generators
Sources of Waste Heat Recovery

Industrial waste heat sources

Gas Turbine Exhaust gases ( 550 Deg C)

Diesel Generator Exhaust ( 450 Degrees C)
Cement Kiln Flue gases ( 350 Deg C)
Steel Reheating Furnace gases ( 400 Deg C)
Iron Sinter waste heat ( 850 Deg C)
Sponge Iron kiln Exhaust Gases ( 850 Deg C)
HRSG Exhaust gases : (140 Deg C)
Boiler Exhaust gases : (180 Deg C)
Reformers ( 450 Deg C)
ORC System – Process schematic

1. Heat from Thermic Fluid will evaporate Organic Fluid.

2. High pressure Organic fluid vapor runs the Turbine
3. Organic vapor is Condensed
4. Liquid organic fluid enters the evaporator. The cycle
continues
Organic Rankine Cycle Turbines
For waste heat recovery
MAIN FEATURES

Can use low temperature heat source ( 90 Deg

C to 300 Deg C)
Available in various capacities (5 KW to 15 MW)
Easy to install ( fully packaged units)
Faster installation ( 6 to 9 months period)
Small form factor, requires less space
Clean technology – no emissions
Faster payback period ( 3 to 3.5 Years)
Organic Rankine Cycle Turbines
(packaged power from waste heat)
270 KW / 550 KW / 1100 KW Modular Units

500 KW to 5000 KW Custom Built Units

Multiple ORC Units
Furnace Waste Heat Recovery
Cement Plant Waste Heat Recovery
Cement Plant Waste Heat Recovery
GTG – HRSG Waste Heat Recovery – CASE STUDY
GTG – HRSG Waste Heat Recovery – CASE STUDY
Gross and Net Power Estimates
Net Exhaust Gas through the
Chimney 328.54 Kg/sec
Exhaust gas Mass Flow rate / Hour 1182744 kg/hr
Exhaust gas Temperature 190 Deg c
Exhaust gas Outlet from WHR heater 96 Deg C
Differential temperature 94 Deg C
Sp Heat capacity 0.25 kcal/kg-Deg C
Heat available for Recovery 27794484 kcal/Hr
WHR heater efficiency 95 %
Heat energy available for ORC 30703.21 KWth
ORC Turbine efficiency 10.5 %
ORC system Gross output 3223.84 Kwe
Auxiliary consumption 250.00 KW
Net Power Output 2973.84 KWe
Number of ORC units ( 270 kw EACH) 12 Nos
GTG – HRSG Waste Heat Recovery – CASE STUDY

Revenue Estimates
Installed capacity 3360
Gross power output 3223.84
Net Power generation 2973.84 Kwe
PLF 0.95
Annual Operating hours 8322 Hrs/Year
Annual Energy generation 24748271.12 Kwh/Yr
Energy tariff 5.50 Rs./Kwh
Revenue from Energy 1361.15 Rs. Lakhs/ Year
GTG – HRSG Waste Heat Recovery – CASE STUDY

Project Economics

Pay Back Period

Project Annual Revenue 1361Rs. Lakhs
Project CAPEX 4365Rs. Lakhs
Simple Payback period 3.21Years
GTG – HRSG Waste Heat Recovery – CASE STUDY
Unit Cost of Energy
Levelised Cost of Energy
CAPEX 4365 Rs. Lakhs
Interest @ 14.5% 7 years 2658 Rs. Lakhs
Total Cost for 7 years 7023 Rs. Lakhs
Cost Per annum 1003 Rs. Lakhs/ Year
Units generated/ Year 24748271 Kwh/Year
Cost per unit 4.05 Rs./kwh
O&M Cost per year @5% 218.25 Rs. Lakhs/ Yr
Operating cost / Unit 0.88 Rs./Kwh
Levelised Cost of Energy 4.94 Rs./Kwh
(First 7 years)
Levelised cost of Energy 0.88 Rs./Kwh
(after 7 years)
Heat Recovery – Chloro Alkali Industry– CASE STUDY
Power Generation Potential and Revenue

HCL Plant capacity 100 TPD

Heat recovery potential 1000 Kcal/Kg
Heat available for recovery 4166667 kcal/Hr
Heat Energy 4844.96 KWth
ORC recovery 1017.44 Kwe
PLF 0.95
Units Generated/ Year 8467151 Kwh/Yr
Energy Tariff 5.5 Rs./Kwh
Revenue from Energy generation 465.69 Rs. Lakhs/Year
Heat Recovery – Chloro Alkali Industry– CASE STUDY
Project Economics

Pay Back Period

Project Annual Revenue 465.69Rs. Lakhs
Project CAPEX 1450Rs. Lakhs
Simple Payback period 3.11Years
Waste Heat Recovery – Other Applications

 Process heating ( Waste heat Recovery boiler)

 Process cooling ( Absorption Chillers)

 Air Conditioning (Absorption Chiller)

 Process drying ( Heat recovery dryer)

Innovative ESCO Business Models

Project Financing

DBOOT ( Design, build, own operate and

transfer) Model with Fixed Installments

PPA model – Financing through Power

purchase agreements

Financing through Equipment / Project leasing

About Our Company

ESCO Company accredited by Bureau of Energy

Efficiency
Energy Company with Global operations with
offices in Dubai, Oman, Athens, Brisbane,
Istanbul, Singapore and Chicago
Expertise in Waste heat recovery and Energy
Efficiency projects for Industry
CRISIL Rated company
Having Large number of ORC projects under
under execution
FREE Energy Study
Send us your waste heat data
We will evaluate the potential for waste
heat recovery and make detailed proposal
to you.
We will make a project proposal with
Economics and profitability estimates.
Mail : Info@Firstesco.in

Dr Vijayakumar : 91-9985502589
First ESCO India Pvt.Ltd.
16, Prince Apartments
Chinna Waltair
VISHAKAPATNAM
www.Firstesco.in
Mobile : 09985502589
Email: info@Firstesco.in