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

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

3. 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

4. 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

5. 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

6. 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

7. 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

8. Furnace heat Loss – Sankey Diagram

9. DG set heat Loss – Sankey Diagram
WHAT IS WASTE HEAT

10. Cement kiln heat Loss – Sankey Diagram

11. Electric Arc Furnace – Energy Balance

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

13. ORC Power systems - Applications
GLASS
CEMENT
SPONGE IRON
PETROLEUM
STEEL

14. 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

15. Organic fluids for ORC

16. 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)

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

18. 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 Deg C
Power range : 250 KW to 10 MW
ORC Fluids : Cyclo pentane, hexane, n-heptane, Tolune
System efficiency : up to 25%

19. 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

20. Carnot Cycle – TS Diagram

21. Steam Cycle – Schematic

22. Steam Cycle – TS Diagram

23. ORC Power systems – TS Diagram

24. ORC Power systems – TS Diagram

25. TS Diagram – Water , Organic Fluids

26. ORC Vs Steam Cycle

27. Steam Cycle – Model Simulation

28. ORC – Model Simulation

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

30. ORC System – Schematic

31. ORC System – Schematic

32. 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

33. FIRST ESCO Low Temperature ORC systems

34. Multiple ORC Units (2.5 MW) with Remote Monitoring

35. 2 MW ORC Units (2.5 MW) with Remote Monitoring

36. Furnace Waste Heat Recovery

37. GTG – HRSG Waste Heat Recovery

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

39. Heat Pipe exchangers – Heat Recovery Boiler

40. Clinker Cooler WHRB

41. Kiln Pre Heater WHRB

42. 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

43. 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 :
Dr Vijayakumar :

44. 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

45. First ESCO India Pvt.Ltd.
16, Prince Apartments
Chinna Waltair
VISHAKAPATNAM, pin , INDIA
Mobile :