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Performance characteristics of a 200-kW organic Rankine cycle system in a steel processing plant

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  • Sung, Taehong
  • Yun, Eunkoo
  • Kim, Hyun Dong
  • Yoon, Sang Youl
  • Choi, Bum Seog
  • Kim, Kuisoon
  • Kim, Jangmok
  • Jung, Yang Beom
  • Kim, Kyung Chun

Abstract

The main objective of this research is to design and build a 200-kW ORC system with reduced size that could be installed in a steel processing plant where space is limited. The real-time operating characteristics of the ORC system are demonstrated with actual flue gases. First, an ORC system with R245fa refrigerant was developed for a heat source temperature of 140°C. The evaporation and condensation pressures were 2,090kPa and 220kPa, respectively. The net power output was 235.7kW with a thermal efficiency of 12.9%. Using an electric heat source, the design point performance of the system is experimentally demonstrated and shows a net power output of 177.4kW with thermal efficiency of 9.6%. The turbine isentropic efficiency and generator efficiency were 68.1% and 98.5% at a rotational speed of 14,000rpm. Next, the ORC system was implemented by designing a dedicated heat transfer loop for a steel processing plant using data measured from a chimney. The experimental net power output is 105.8kW with a thermal efficiency of 8.6% when the plant is operated at the highest work load. The fluctuation of the flue gas temperature is successfully suppressed with a thermal storage tank installed in the heat transfer loop. A partial-load analysis was conducted and showed that the system has the highest performance with more than 165kW of net power output. Economic analysis of such system showed that the right sized ORC system with always working parent plant had good economics with a payback period of 9years.

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  • Sung, Taehong & Yun, Eunkoo & Kim, Hyun Dong & Yoon, Sang Youl & Choi, Bum Seog & Kim, Kuisoon & Kim, Jangmok & Jung, Yang Beom & Kim, Kyung Chun, 2016. "Performance characteristics of a 200-kW organic Rankine cycle system in a steel processing plant," Applied Energy, Elsevier, vol. 183(C), pages 623-635.
    • Handle: RePEc:eee:appene:v:183:y:2016:i:c:p:623-635
    DOI: 10.1016/j.apenergy.2016.09.018
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    4. Feng, Yong-qiang & Hung, Tzu-Chen & Su, Ting-Ying & Wang, Shuang & Wang, Qian & Yang, Shih-Cheng & Lin, Jaw-Ren & Lin, Chih-Hung, 2017. "Experimental investigation of a R245fa-based organic Rankine cycle adapting two operation strategies: Stand alone and grid connect," Energy, Elsevier, vol. 141(C), pages 1239-1253.
    5. Magdalena Santos-Rodriguez, M. & Flores-Tlacuahuac, Antonio & Zavala, Victor M., 2017. "A stochastic optimization approach for the design of organic fluid mixtures for low-temperature heat recovery," Applied Energy, Elsevier, vol. 198(C), pages 145-159.
    6. Al Jubori, Ayad M. & Al-Dadah, Raya K. & Mahmoud, Saad & Daabo, Ahmed, 2017. "Modelling and parametric analysis of small-scale axial and radial-outflow turbines for Organic Rankine Cycle applications," Applied Energy, Elsevier, vol. 190(C), pages 981-996.
    7. Jiménez-Arreola, Manuel & Pili, Roberto & Wieland, Christoph & Romagnoli, Alessandro, 2018. "Analysis and comparison of dynamic behavior of heat exchangers for direct evaporation in ORC waste heat recovery applications from fluctuating sources," Applied Energy, Elsevier, vol. 216(C), pages 724-740.
    8. Majumdar, Rudrodip & Saha, Sandip K. & Singh, Suneet, 2018. "Evaluation of transient characteristics of medium temperature solar thermal systems utilizing thermal stratification," Applied Energy, Elsevier, vol. 224(C), pages 69-85.
    9. Al Jubori, Ayad M. & Al-Dadah, Raya & Mahmoud, Saad, 2017. "Performance enhancement of a small-scale organic Rankine cycle radial-inflow turbine through multi-objective optimization algorithm," Energy, Elsevier, vol. 131(C), pages 297-311.
    10. Lecompte, Steven & Gusev, Sergei & Vanslambrouck, Bruno & De Paepe, Michel, 2018. "Experimental results of a small-scale organic Rankine cycle: Steady state identification and application to off-design model validation," Applied Energy, Elsevier, vol. 226(C), pages 82-106.
    11. Majumdar, Rudrodip & Singh, Suneet & Saha, Sandip K., 2018. "Quasi-steady state moving boundary reduced order model of two-phase flow for ORC refrigerant in solar-thermal heat exchanger," Renewable Energy, Elsevier, vol. 126(C), pages 830-843.
    12. Couvreur, Kenny & Beyne, Wim & De Paepe, Michel & Lecompte, Steven, 2020. "Hot water storage for increased electricity production with organic Rankine cycle from intermittent residual heat sources in the steel industry," Energy, Elsevier, vol. 200(C).
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