Implementation of simulated annealing method on optimization of organic Rankine cycle waste heat recovery power generation from a two-stream heat source

Abstract The accelerating growth of electricity demand necessitates looking for potential waste heat recovery solutions in production industries. Significant potential for efficient waste heat recovery is observed in the cement manufacturing industry. Based on the waste heat source temperatures in a cement plant, two potential candidates, the supercritical CO2 Brayton (S-CO2) cycle or the Organic Rankine cycle (ORC), promises low capital cost and enhanced thermodynamic performance. The current study focuses on modelling and optimization of the S-CO2 and ORC cycles for a 1 MTPA cement plant, with the raw-clinker preheater as the waste-heat source. The primary objective is to maximize the net-power output using genetic algorithms. A comparative performance analysis of the two ORCs with working fluids: R134a and Propane, the simply recuperated S-CO2 cycle (RC) and recompressed-recuperated S-CO2 cycle (RRC) configurations is presented with varying number of preheaters. For all cases, ORC-R134a yields more power than the ORC-Propane, RC, and RRC configurations. In terms of the waste heat recovered, ORC-Propane marginally outperforms ORC-R134a. The ORC configurations recover 32%–38% of the available heat, while the S-CO2 configurations recover, at maximum, 25%–30% of the available heat.

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Optimization of Organic Rankine Cycle Waste Heat Recovery for Power Generation in a Cement Plant via Response Surface Methodology

International Journal of Technology ◽

10.14716/ijtech.v6i6.1695 ◽

2015 ◽

Vol 6 (6) ◽

pp. 938 ◽

Cited By ~ 3

Author(s):

Hendi Riyanto ◽

Sigit Yoewono Martowibowo

Keyword(s):

Power Generation ◽

Response Surface Methodology ◽

Response Surface ◽

Heat Recovery ◽

Waste Heat Recovery ◽

Waste Heat ◽

Organic Rankine Cycle ◽

Rankine Cycle ◽

Cement Plant

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Design of an Organic Rankine Cycle for Waste Heat Recovery From a Portable Diesel Generator

Volume 4: Energy Systems Analysis, Thermodynamics and Sustainability; Combustion Science and Engineering; Nanoengineering for Energy, Parts A and B ◽

10.1115/imece2011-65489 ◽

2011 ◽

Cited By ~ 1

Author(s):

Frederick J. Cogswell ◽

David W. Gerlach ◽

Timothy C. Wagner ◽

Jarso Mulugeta

Keyword(s):

Power Generation ◽

Heat Exchanger ◽

Heat Recovery ◽

High Speed ◽

Waste Heat Recovery ◽

Waste Heat ◽

Organic Rankine Cycle ◽

Rankine Cycle ◽

Diesel Generator ◽

Air Conditioners

A 5-kW Organic Rankine Cycle (ORC) was designed for mobile 60-kW diesel engine waste heat recovery applications to provide additional electricity for powering air conditioners. The ORC uses a non-flammable, near-zero-global-warming-potential fluid (Novec649) in a supercritical cycle. The system conceptual design and some observations on the component specification are described. The system will utilize an advanced oil-free high speed direct drive turbine. The proposed power generation module has a volume of ∼3 ft3 and contains the turbine, generator, pump, recuperator, and electrical components. The heat rejection heat exchanger is located on the power generation module in a configuration similar to mini-split air conditioners. The heat recovery heat exchanger (supercritical heater) is attached to the diesel generator and placed in series before the OEM muffler. The supercritical heater must be carefully designed to prevent the refrigerant from overheating, while still maintaining a high effectiveness.

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Waste Heat Recovery Power Generation by ORC “Organic Rankine Cycle”

Marine Engineering ◽

10.5988/jime.48.163 ◽

2013 ◽

Vol 48 (2) ◽

pp. 163-166

Author(s):

Takatsugu Yuki ◽

Masayuki Kawami

Keyword(s):

Power Generation ◽

Heat Recovery ◽

Waste Heat Recovery ◽

Waste Heat ◽

Organic Rankine Cycle ◽

Rankine Cycle

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Preliminary Design of a Lab-Scale Organic Rankine Cycle for Waste Heat Recovery Applications

Volume 6B: Energy ◽

10.1115/imece2018-86434 ◽

2018 ◽

Author(s):

Carlos Cabezas ◽

José Mendoza ◽

Iván Ponce ◽

Rafael Cantorin ◽

Daniel Gonzales ◽

...

Keyword(s):

Heat Source ◽

Heat Recovery ◽

Waste Heat Recovery ◽

Waste Heat ◽

Combustion Engine ◽

Organic Rankine Cycle ◽

Rankine Cycle ◽

Internal Combustion ◽

Working Fluid ◽

Preliminary Design

This work describes the preliminary design of a lab-scale organic Rankine cycle (ORC) for waste heat recovery based applications. As heat source for the ORC, exhaust gases from an actual internal combustion engine are utilized. The design is primarily carried out accounting for the working fluid path. More specifically, a brief introduction to be subject is initially provided. The details of the ORC preliminary design are discussed next. This includes the selection of the main working fluid, the definition of the ORC plant layout and the design of the main ORC plant components. The specifics of an overall control loop resembling an actual control system that could be used in the designed ORC based plant is also provided. In terms of power output, the results show that up to 1.68 kW can be produced from the waste heat of internal combustion engines like the one accounted for in this work. Compared to the shaft power (25.1 kW) associated with the internal combustion engine providing the heat source, this power output represents about 7%. The preliminary design described here constitutes the first step of a large effort aiming to build, install and test a lab-scale ORC for educational purposes. It is expected that such ORC based plant allows carrying out in future several studies, including the development of different control strategies for maximizing the operational performance of these plants.

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Component-Oriented Modeling of a Micro-Scale Organic Rankine Cycle System for Waste Heat Recovery Applications

Applied Sciences ◽

10.3390/app11051984 ◽

2021 ◽

Vol 11 (5) ◽

pp. 1984

Author(s):

Ramin Moradi ◽

Emanuele Habib ◽

Enrico Bocci ◽

Luca Cioccolanti

Keyword(s):

Electric Power ◽

Heat Recovery ◽

Waste Heat Recovery ◽

Waste Heat ◽

Organic Rankine Cycle ◽

Rankine Cycle ◽

Operating Conditions ◽

Working Fluid ◽

Pump Efficiency ◽

Micro Scale

Organic Rankine cycle (ORC) systems are some of the most suitable technologies to produce electricity from low-temperature waste heat. In this study, a non-regenerative, micro-scale ORC system was tested in off-design conditions using R134a as the working fluid. The experimental data were then used to tune the semi-empirical models of the main components of the system. Eventually, the models were used in a component-oriented system solver to map the system electric performance at varying operating conditions. The analysis highlighted the non-negligible impact of the plunger pump on the system performance Indeed, the experimental results showed that the low pump efficiency in the investigated operating range can lead to negative net electric power in some working conditions. For most data points, the expander and the pump isentropic efficiencies are found in the approximate ranges of 35% to 55% and 17% to 34%, respectively. Furthermore, the maximum net electric power was about 200 W with a net electric efficiency of about 1.2%, thus also stressing the importance of a proper selection of the pump for waste heat recovery applications.

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