DOCSLIB.ORG

Perspectives for Power Generation from Industrial Waste Heat Recovery

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Perspectives for Power Generation from Industrial Waste Heat Recovery Perspectives for Power Generation from Industrial Waste Heat Recovery Fanny Blanquart Master of Science Thesis KTH School of Industrial Engineering and Management Energy Technology EGI_2017-0010 MSC EKV 1176 Division of Heat & Power SE-100 44 STOCKHOLM Master of Science Thesis EGI_2017-0010 MSC EKV 1176 Perspectives for Power Generation from Industrial Waste Heat Recovery Fanny Blanquart Approved Examiner Supervisor 2017-04-25 Miroslav Petrov - KTH/ITM/EGI Miroslav Petrov Commissioner Contact person Siemens AG Thomas Schille Abstract This thesis work was carried out at Siemens in Germany in the department of Steam Turbines, and aims to raise awareness of the potential for broader deployment of waste heat recovery (WHR) from industrial processes for power generation. Technologies available to recover heat are presented and sorted out according to the features of the heat source. In particular, ORC and water-based cycles are compared in terms of efficiency and other advantages and their sensitivity to variable parameters. As far as the efficiency is concerned, the type of technology does seem to have less impact than the size of the installation. Organic fluid cycles have properties that could encourage their selection, like smaller size of equipment, better efficiency during off- design operations or no make-up water supply. This study also presents different segments where WHR systems are possible. In the short term, cement, electric arc furnace and glass industries are the sectors that offer the best opportunities for WHR integrated with power generation. In a long-term view, future large systems for power generation tend to disappear with the expected optimization of the industrial processes. Instead, there would be opportunities to develop waste heat recovery systems for non-continuous flows and low temperature streams coming for instance from cooling processes. Considering the progress in technologies development in the past years, understanding the economic environment is the real challenge to develop a WHR market. Technologies are indeed available but often too expensive or not sufficiently well-known by the industrial players. In that context, subsidies from national governments or organizations can be a crucial option to push the development forward. Nevertheless, the comparative evaluation shows that the rising costs of energy in the future will inevitably provide more opportunities for market-ready WHR systems. Contents 1 Introduction .......................................................................................................................................................... 1 1.1 Introduction ................................................................................................................................................. 1 1.2 Statement of the problem .......................................................................................................................... 2 1.3 Background and need ................................................................................................................................. 3 1.4 Purpose of the study ................................................................................................................................... 3 1.4.1 Research questions ............................................................................................................................. 4 1.4.2 Scope of research and limitations .................................................................................................... 4 2 Literature review ................................................................................................................................................... 5 2.1 Introduction ................................................................................................................................................. 5 2.2 Sources of waste heat ................................................................................................................................. 5 2.2.1 Waste Heat Definition ...................................................................................................................... 5 2.2.2 Waste Heat Estimation ..................................................................................................................... 6 2.3 The power generation technologies ......................................................................................................... 7 2.3.1 Rankine Turbine Cycle ...................................................................................................................... 8 2.3.2 Other technology than Rankine cycle ........................................................................................... 17 2.4 Economic Potential .................................................................................................................................. 22 2.5 Conclusion ................................................................................................................................................. 23 3 Method ................................................................................................................................................................. 24 3.1 Introduction ............................................................................................................................................... 24 3.2 Setting ......................................................................................................................................................... 24 3.3 Participants ................................................................................................................................................. 24 3.4 Data collection ........................................................................................................................................... 24 3.5 Calculation .................................................................................................................................................. 25 3.6 Data analysis............................................................................................................................................... 27 3.7 Conclusion ................................................................................................................................................. 28 4 Results .................................................................................................................................................................. 29 4.1 Technologies .............................................................................................................................................. 29 4.1.1 Water/Steam Turbine Cycle .......................................................................................................... 29 4.1.2 ORC Optimization .......................................................................................................................... 31 4.1.3 Configurations of the Rankine Cycle ............................................................................................ 35 4.1.4 Technology overview ...................................................................................................................... 43 4.2 Segments ..................................................................................................................................................... 47 4.2.1 Technical barriers ............................................................................................................................. 48 4.2.2 Iron and Steel industry .................................................................................................................... 50 4.2.3 Cement industry ............................................................................................................................... 55 -i- 4.2.4 Glass industry ................................................................................................................................... 59 4.2.5 Aluminum industry .......................................................................................................................... 62 4.2.6 Chemical - Petroleum ...................................................................................................................... 63 4.2.7 Conclusion ........................................................................................................................................ 65 4.3 Economic Environment .......................................................................................................................... 67 4.3.1 Installations Costs ............................................................................................................................ 67 4.3.2 Payback consideration ..................................................................................................................... 69 4.3.3 Players ................................................................................................................................................ 71 4.3.4 Drivers and Barriers ........................................................................................................................ 72 5 Discussion ........................................................................................................................................................... 74 5.1 Discussion .................................................................................................................................................
Load more

Recommended publications
  • Water Treatment for Fossil Fuel Power Generation
    WATER TREATMENT FOR FOSSIL FUEL POWER GENERATION Report No. COAL R300 DTI/Pub URN 06/705 January 2006 by Dr Alan Paton, Paul McCann and Nick Booth E.ON UK plc, Power Technology Centre, Ratcliffe on Soar, Nottingham, NG11 OEE Tel: 0115 936 2000 Fax: 0115 936 2711 www.eon-uk.com The work described in this report was carried out under contract as part of the DTI Cleaner Coal Technology Transfer Programme. The programme is managed by Future Energy Solutions. The views and judgements expressed in this report are those of the contractor and do not necessarily reflect those of the DTI or Future Energy Solutions First published 2005 © Crown copyright 2005 EXECUTIVE SUMMARY A ‘Technology Status Review of Water Treatment Associated with Fossil Fuel Based Power Generation and Related Processes’ has been completed for AEA Technology plc (AEAT), on behalf of the UK Department of Trade and Industry (DTI). The aims of the review were to:- • Assess objectively the current state of development and application of water treatment technologies relating to fossil fuel power generation world-wide. • Critically assess the strengths and shortcomings of existing technologies in relation to commercial or near-commercial needs and to provide information on manufacturers, suppliers, developers, consultants and major users. • Review current activities and capabilities of companies/organisations working in the water treatment technology sector, with particular emphasis on the UK. • Identify priority areas in which UK RD&D activities could/should be focused to meet future demands. • Recommend means for enhancing the market opportunities for UK companies and organisations specialising in water treatment technologies.
    [Show full text]
  • Thermodynamic Analysis for Improving Understanding and Performance of Hybrid Power Cycles Using Multiple Heat Sources of Different Temperatures
    University of Pennsylvania ScholarlyCommons Publicly Accessible Penn Dissertations 2017 Thermodynamic Analysis For Improving Understanding And Performance Of Hybrid Power Cycles Using Multiple Heat Sources Of Different Temperatures Ting Yue University of Pennsylvania, [email protected] Follow this and additional works at: https://repository.upenn.edu/edissertations Part of the Mechanical Engineering Commons, and the Oil, Gas, and Energy Commons Recommended Citation Yue, Ting, "Thermodynamic Analysis For Improving Understanding And Performance Of Hybrid Power Cycles Using Multiple Heat Sources Of Different Temperatures" (2017). Publicly Accessible Penn Dissertations. 2658. https://repository.upenn.edu/edissertations/2658 This paper is posted at ScholarlyCommons. https://repository.upenn.edu/edissertations/2658 For more information, please contact [email protected]. Thermodynamic Analysis For Improving Understanding And Performance Of Hybrid Power Cycles Using Multiple Heat Sources Of Different Temperatures Abstract Past studies on hybrid power cycles using multiple heat sources of different temperatures focused mainly on case studies and almost no general theory about this type of systems has been developed. This dissertation is a study of their general thermodynamic performance, with comparisons to their corresponding single heat source reference systems. The method used in the dissertation was step-wise: to first analyze the major hybrid power cycles (e.g. Rankine, Brayton, Combined Cycles, and their main variants) thermodynamically,
    [Show full text]
  • Proper Care and Feeding of Your Deaerating Feedwater Heater
    PROPER CARE AND FEEDING OF YOUR DEAERATING FEEDWATER HEATER The deaerating feedwater heater is one of the most important components of the steam generation cycle in a boiler plant. Besides heating the feedwater, it also liberates and removes the non-condensable gases (primarily Oxygen and Carbon Dioxide) present in the water. These gases would cause pitting and corrosion if allowed to enter the boiler with the feedwater. A good quality deaerator should be constructed to conform to the requirements of the “Deaerator Standard” from the Heat Exchange Institute (HEI). HEI is acknowledged worldwide as the leading standards development organization for heat exchange and vacuum apparatus. By understanding how the deaerator works and knowing what to check regarding its operation, the owner can very easily monitor the deaerator’s efficiency and react accordingly when operating conditions go awry. The feedwater heater is an ASME Code pressure vessel where condensate and soft make-up water enter the top of the shell and are distributed through spray nozzles traveling downward through a series of distribution trays. The combination of the action of the spray nozzles and the water cascading through the very small openings in the distribution trays breaks the water down into minute droplets. As low pressure steam introduced at the bottom of the vessel flows upward through the spray water the water and the steam come into direct contact with each other. This direct contact of water and steam serves two purposes: 1) The water absorbs heat from the steam, thus raising its temperature 2) The hot steam drives off corrosive gases (Oxygen and Carbon Dioxide) entrained in the water, removing them through an atmospheric vent at the top of the heater shell.
    [Show full text]
  • Coal-Fired Advanced Supercritical Retrofit with CO2 Capture
    Coal-Fired Advanced Supercritical Retrofit with CO2 Capture Contract No.: C/08/00393/00/00 URN 09D/739 June 2009 Coal-Fired Advanced Supercritical Retrofit with CO2 Capture Contract No.: C/08/00393/00/00 URN 09/739 Contractor Doosan Babcock Energy Limited The work described in this report was carried out under contract, initially as part of the DTI Emerging Energy Technologies Programme and latterly under the Technology Strategy Board. It is one of a number of energy projects managed by AEA Technology. The views and judgments expressed in this report are those of the contractor and do not necessarily reflect those of DECC, the Technology Strategy Board or AEA Technology. First Published 2007 © Crown Copyright 2007 i Lead Contractor Doosan Babcock Energy Limited Porterfield Road Renfrew PA4 8DJ Tel: +44 (0) 141 886 4141 Fax: +44 (0) 141 885 3370 E-mail: [email protected] Web: www.doosanbabcock.com Collaborators Alstom E.ON UK Air Products plc Imperial College London Fluor Ltd Sponsors E.ON UK Drax Power Ltd EDF Energy Scottish and Southern Energy RWEnpower ScottishPower Prepared by R S Panesar Doosan Babcock Energy Limited Porterfield Road Renfrew PA4 8DJ Tel: +44 (0)141 885 3921 www.doosanbabcock.com M R Lord Alstom Power Ltd. Newbold Road Rugby Warwickshire CV21 2NH Tel: +44 (0)1788 531045 www.power.alstom.com S T Simpson E.ON UK PLC Power Technology Ratcliffe-on-Soar Nottingham NG11 0EE Tel: +44 (0) 2476 192479 www.eon-uk.com V White Air Products PLC Hersham Place Molesey Road Walton-on-Thames Surrey KT12 4RZ Tel: +44 (0)1932
    [Show full text]
  • Deaerating Condenser Boosts Combined-Cycle Plant Efficiency
    Deaerating condenser boosts combined-cycle plant efficiency Studies show savings in equipment and plant space and the ability to deaerate large quantities of makeup water using only turbine exhaust steam in a new system BY R.E. ATHEY AND E. SPENCER, GRAHAM MANUFACTURING CO. new system of steam condenser dissolved oxygen control has at or near the design cooling water temperature, and then only if Afound favor in the combined-cycle cogeneration market. air leakage is reduced to 25% of tabulated values for flows up to Savings in equipment, a reduction in building size (and plant 20 scfm, and to 15% of tabulated values for flows up to 40 scfm. height), and the ability to deaerate large quantities of makeup Maximum air leakage in any case may not exceed 6 scfm. water using only turbine exhaust steam are the reasons. Reports by the Electric Power Research Institute (EPRI) consis- In earlier days, no condenser manufacturer guaranteed condensate tently describe DO increases during start-up and at reduced load. oxygen levels of 7 parts per billion (ppb) under any operating Specifically, EPRI NP-2294 attributes high dissolved oxygen in condition. Instead, guarantees were limited to Heat Exchange steam condenser condensate to inadequate venting at reduced Institute (HEI) standards. load. This report indicates that the steam condenser air cooling section became ineffective under partial load conditions. The HEI standards promise 0.005 cc/I (7 ppb) dissolved oxygen (DO) resultant increased vapor tends to overload the vent system at the in the condensate only if (1) the air leakage is reduced to a frac- same time as the vent system capacity is reduced at lower con- tion of the tabulated leakage rates; (2) the condenser makeup is denser pressures.
    [Show full text]
  • Powerplant Chemistry® Journal
    PowerPlant Chemistry PowerPlant Chemistry Contents 1999-2000 (Volume 1 and 2) Issue Author(s) Title Key Words 1999, 1 (1) Michael Rziha Cycle Chemistry in Combined Cycle Units - Combined Cycles, HRSG, Cycle Rainer Wulff The Siemens Experience Chemistry Digby D. Macdonald Deterministic Prediction of Localized Corrosion BWR, IGSCC, Crack Growth Rate, louri Balachov Damage in Power Plant Coolant Circuits Modeling George Engelhardt Gernot Repphun Influence of Metal Addition to BWR Water on BWR, Co-58 Activity, Metal Ions Andreas Hiltpold Contamination and Corrosion of Stainless Addition Irene Mailand Steel Bernhard Stellwag James C. Bellows Chemical Processes in Steam Turbines Steam Chemistry, Thermodynamics Joachim Fahlke RO Applications and Wastewater Reuse - Two Reverse Osmosis, Wastewater Important Fossil Power Plant Contributions Reuse to Conservation of Water Resources Daniel E. Meils Performance Assessment of Chemistry On-line On-Line Monitoring Process Instrumentation Issue Author(s) Title KeyWords 1999, 1 (2) Jan Stodola Review of Conditions for Reliable Boiler Boiler Water Treatment Operation Karol Daucik Water/Steam Cycle Chemistry of Ultra Ultra Supercritical Units, Materials, Supercritical Units Condensate Polishing, Tamara I. Petrova Effect of Demineralized Water Purity on Carbon Steel Corrosion Corrosion of Carbon Steel Heinrich Maurer On-line pH Monitoring by Measuring On-Line Monitoring, pH, Differential Cation and Specific Conductivity Conductivity Rene van der Wagt On-line Analysis of Water Contamination by On-Line Monitoring,
    [Show full text]