First ESCO India Pvt. Ltd. ORC Technology for waste Heat Recovery Power Generation First ESCO India Pvt. Ltd.

Barriers to Waste Heat Recovery Technological Barriers Financial Barriers Risk-Reward imbalance

Waste Heat – Technological barriers Technology is available for high temperature recovery using conventional HRSG ( heat recovery steam generators) and Steam turbine Generators using Rankine cycle Rankine cycle is not suitable for Low temperature heat recovery

Waste Heat – Financial barriers ORC technology for Low grade heat recovery is available in Europe and other parts of the world. But the systems are Too expensive to adapt Pay back period is too long Economically not feasible due to the subisidised electricity tariffs

Waste Heat – Risk reward Imbalance Any new technology, users would initially perceive high risk If the economic benefit due to the technology is not sustainable due to High Capital expenditure, there is no motivation to take the RISK

Waste Heat - Present situation Industrial Processes use Oil, Gas , Coal or electricity for Heating Furnaces, heaters, Boilers, reformers, reactors, kilns etc. reject 30 to 40% heat to the atmosphere through Exhaust Flue gas. Higher temperature exhaust gases ( >300 Deg C) are already used in the process for pre heating, or co generation using CHP technologies How ever exhaust gases below 300 Deg C are not used due to low efficiency of conventional Rankine cycle and non availability of sustainable technology

Sources for Waste Heat Recovery Gas Turbine Exhaust Gases 550 Deg C Diesel generator set Exhaust Gases 450 Cement Kiln - PH exhaust Gases 320 Cement Kiln - Cooler Exhaust Gases 350 Steel Reheat Furnace 400 HRSG Exhaust Gases 140 Boiler Exhaust Gases 180 Oil Fired Furnaces ( petroleum & Chemicals) 150 Engine Jacket Cooling water 90

Furnace heat Loss – Sankey Diagram

DG set heat Loss – Sankey Diagram WHAT IS WASTE HEAT

Cement kiln heat Loss – Sankey Diagram

Electric Arc Furnace – Energy Balance

HEAT = MONEY Why Heat Recovery Convert Heat in the Exhaust gas to Power

ORC Power systems - Applications GLASS CEMENT SPONGE IRON PETROLEUM STEEL

What IS ORC SYSTEM ? ORC Stands for Organic Rankine Cycle. ORC systems use Organic Fluid in place of water In a ORC system Organic Fluid vapor will drive the Turbine in place of Steam ( Rankine Cycle) ORC systems can work on Low temperature Heat resources ORC systems are best suited for Low temperature Heat Recovery Organic fluids : R234fa, R 134 , Pentane, Cyclo-pentane, n- Heptane, hexane, Toluene

Organic fluids for ORC

ORC Power systems - FEATURES Organic fluids have low specific consumption of vapor in the Turbine expander Plants work on Closed Loop control and automation Suitable for remote monitoring and control Very Low maintenance and operating cost Very stable and SAFE to operate, Provided with automatic flame detection and CO2 flooding system Faster supply Construction period ( maximum 6 to 9 months) Faster Pay back period ( less than 3 years)

ORC –Safety considerations Gas detectors Flame detectors Automated Foam dispensers Automated CO2 Fire extinguishing systems CCOE Approval

ORC SYSTEMS - AVAILABILITY High Temperature ORC systems Temperature Range : 70 Deg C to 170 Deg C Power range : 10 KW to 1000 KW ORC Fluids : R245 Fa, R134, 3M Fluids Ssystem efficiency : up to 14% Low Temperature ORC systems Temperature Range : 170 Deg C 70 300 Deg C Power range : 250 KW to 10 MW ORC Fluids : Cyclo pentane, hexane, n-heptane, Tolune System efficiency : up to 25%

Potential for ORC Power systems 50 M3/ Hr Hot water available at 140 Deg C can generate 280 Kwe Gross power 200 Tons / Hr Hot water at 90 Deg C can generate 500 Kwe power 150 Tons/ hr Hot Flue Gas at 300 Deg C can generate 1000 Kwe Gross power

Carnot Cycle – TS Diagram

Steam Cycle – Schematic

Steam Cycle – TS Diagram

ORC Power systems – TS Diagram

ORC Power systems – TS Diagram

TS Diagram – Water , Organic Fluids

ORC Vs Steam Cycle

Steam Cycle – Model Simulation

ORC – Model Simulation

ORC – Steam Cycle Comparison ORC Systems have Higher Conversion efficiency than Steam Cycle for temperatures less than 350 Deg C

ORC System – Schematic

ORC System – Schematic

FIRST ESCO High Efficiency ORC systems Parameter Units FE-500 FE-1000 FE-2000 FE-3000 FE-5000 Hot oil flow rate kg/Hr 34000 68000 136000 204000 340000 Hot oil inlet temperature Deg C 280 Hot oil outlet temperature 180 Thermal input to ORC MWth 2.17 4.35 8.70 13.05 21.74 Cooling water inlet temperature 39 Cooling water Outlet temperature 29 Gross Power output Kwe 500 1000 2000 3001 5001 Net Power output 450 900 1800 2701 4501

FIRST ESCO Low Temperature ORC systems

Multiple ORC Units (2.5 MW) with Remote Monitoring

2 MW ORC Units (2.5 MW) with Remote Monitoring

Furnace Waste Heat Recovery

GTG – HRSG Waste Heat Recovery

Heat Recovery power Generation – 50 Ton EAF Hot Flue gas flow rate : 80000 NM3/Hr Flue gas Temp before GCT : 600 Deg C Operating Cycle : 1 Hour on 1 hour off

Heat Pipe exchangers – Heat Recovery Boiler

Clinker Cooler WHRB

Kiln Pre Heater WHRB

Innovative Business Models Project is Offered by FIRST ESCO through innovative business models BOT Model 20% investment by Mahindra Sanyo and 80% Funding by FIRST ESCO. Monthly EMI payment by Customer. At the end of the period Plant is handed over to the customer PPA Model 100% Funding by FIRST ESCO, Customer signs a Power purchase agreement. At the end of the period plant is sold to Customer at nominal price

We invite Enquiries Mail : Info@Firstesco.in End users with Waste Heat source interested in Heat Recovery Power generation IPP ( Independent Power producers) Investors willing to be associated with ORC power Projects Energy Auditors interested in Waste Heat Recovery projects Mail : Info@Firstesco.in Dr Vijayakumar : +91-9985502589

About Our Company ESCO Company accredited by Bureau of Energy Efficiency, Power Ministry, India Energy Company with Global operations with offices in Dubai, Athens, Ankara and Chicago In house Engineering and Technology for ORC systems CRISIL Rated company Having US$ 50 Million Heat recovery ORC projects at various stages of execution

First ESCO India Pvt.Ltd. 16, Prince Apartments Chinna Waltair VISHAKAPATNAM, pin 530017, INDIA www.Firstesco.in Mobile : 91-9985502589 Email: info@Firstesco.in