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Thermal and economic assessment of organic Rankine cycles for waste heat recovery in cement plants

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  • Moreira, L.F.
  • Arrieta, F.R.P.

Abstract

This work aimed to investigate the thermodynamic and economic performance of simple and regenerative organic Rankine cycles (ORCs) working under subcritical and subcritical conditions, with superheating operating conditions. These were used in waste heat recovery (WHR) in Brazilian cement factories with clinker productive capacities from (3000 to 6300) ton/d. After selecting the most appropriate organic fluids, the cycles were modelled in terms of their thermodynamic and economic properties using Engineering Equation Solver (EES) software. The key operating parameters of the cycles were optimized using the same software via the genetic algorithm method. The results show that the organic fluids with highest performance from the point of view of their net power output, thermal and exergy efficiencies were R141b, R11, and R123. For all the cycles analysed, the payback period was less than two years, the net present value varied from 130 to 170 million reais, and the internal rate of return exceeded 80%/year. In addition, the proposed ORCs were able to produce around (4000–9000) kW (or ~80 MW for the cement sector of the Minas Gerais state in Brazil, thus eliminating the production of 221,069 kgCO2/year), and had to reach specific costs of investment and specific electricity generation costs ranging from (2250 to 4300) R$/kW and (0.09–0.11) R$/kWh, respectively. Based on the obtained results, we can conclude that the proposed ORCs for WHR in the Brazilian cement industry are environmentally interesting and extremely competitive in terms of their financial and technical properties.

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  • Moreira, L.F. & Arrieta, F.R.P., 2019. "Thermal and economic assessment of organic Rankine cycles for waste heat recovery in cement plants," Renewable and Sustainable Energy Reviews, Elsevier, vol. 114(C), pages 1-1.
    • Handle: RePEc:eee:rensus:v:114:y:2019:i:c:48
    DOI: 10.1016/j.rser.2019.109315
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    Cited by:

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    4. Chen, Heng & Wang, Yihan & An, Liuming & Xu, Gang & Zhu, Xin & Liu, Wenyi & Lei, Jing, 2022. "Performance evaluation of a novel design for the waste heat recovery of a cement plant incorporating a coal-fired power plant," Energy, Elsevier, vol. 246(C).
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    8. Zhang, Hongsheng & Liu, Xingang & Liu, Yifeng & Duan, Chenghong & Dou, Zhan & Qin, Jiyun, 2021. "Energy and exergy analyses of a novel cogeneration system coupled with absorption heat pump and organic Rankine cycle based on a direct air cooling coal-fired power plant," Energy, Elsevier, vol. 229(C).
    9. Shuozhuo Hu & Zhen Yang & Jian Li & Yuanyuan Duan, 2021. "A Review of Multi-Objective Optimization in Organic Rankine Cycle (ORC) System Design," Energies, MDPI, vol. 14(20), pages 1-36, October.
    10. Sayed, Enas Taha & Abdelkareem, Mohammad Ali & Bahaa, Ahmed & Eisa, Tasnim & Alawadhi, Hussain & Al-Asheh, Sameer & Chae, Kyu-Jung & Olabi, A.G., 2021. "Synthesis and performance evaluation of various metal chalcogenides as active anodes for direct urea fuel cells," Renewable and Sustainable Energy Reviews, Elsevier, vol. 150(C).
    11. Zhang, Xiaofeng & Su, Junjie & Jiao, Fan & Zeng, Rong & Pan, Jinjun & He, Xu & Deng, Qiaolin & Li, Hongqiang, 2024. "Performance investigation and operation optimization of an innovative hybrid renewable energy integration system for commercial building complex and hydrogen vehicles," Energy, Elsevier, vol. 301(C).
    12. Marenco-Porto, Carlos A. & Fierro, José J. & Nieto-Londoño, César & Lopera, Leonardo & Escudero-Atehortua, Ana & Giraldo, Mauricio & Jouhara, Hussam, 2023. "Potential savings in the cement industry using waste heat recovery technologies," Energy, Elsevier, vol. 279(C).
    13. Kolahchian Tabrizi, Mehrshad & Bonalumi, Davide, 2022. "Techno-economic performance of the 2-propanol/1-butanol zeotropic mixture and 2-propanol/water azeotropic mixture as a working fluid in Organic Rankine Cycles," Energy, Elsevier, vol. 246(C).
    14. Danyang Cheng & David M. Reiner & Fan Yang & Can Cui & Jing Meng & Yuli Shan & Yunhui Liu & Shu Tao & Dabo Guan, 2023. "Projecting future carbon emissions from cement production in developing countries," Nature Communications, Nature, vol. 14(1), pages 1-12, December.
    15. Alklaibi, A.M. & Lior, N., 2021. "Waste heat utilization from internal combustion engines for power augmentation and refrigeration," Renewable and Sustainable Energy Reviews, Elsevier, vol. 152(C).
    16. Ping, Xu & Yang, Fubin & Zhang, Hongguang & Xing, Chengda & Wang, Chongyao & Zhang, Wujie & Wang, Yan, 2022. "Energy, economic and environmental dynamic response characteristics of organic Rankine cycle (ORC) system under different driving cycles," Energy, Elsevier, vol. 246(C).
    17. Ofosu-Adarkwa, Jeffrey & Xie, Naiming & Javed, Saad Ahmed, 2020. "Forecasting CO2 emissions of China's cement industry using a hybrid Verhulst-GM(1,N) model and emissions' technical conversion," Renewable and Sustainable Energy Reviews, Elsevier, vol. 130(C).

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