IDEAS home Printed from https://ideas.repec.org/a/eee/rensus/v114y2019ic48.html
   My bibliography  Save this article

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

Author

Listed:
  • 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.

Suggested Citation

  • 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
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S1364032119305234
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.rser.2019.109315?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Chaitanya Prasad, G.S. & Suresh Kumar, C. & Srinivasa Murthy, S. & Venkatarathnam, G., 2015. "Performance of an organic Rankine cycle with multicomponent mixtures," Energy, Elsevier, vol. 88(C), pages 690-696.
    2. Sarkar, Jahar & Bhattacharyya, Souvik, 2015. "Potential of organic Rankine cycle technology in India: Working fluid selection and feasibility study," Energy, Elsevier, vol. 90(P2), pages 1618-1625.
    3. Shao, Long & Ma, Xinling & Wei, Xinli & Hou, Zhonglan & Meng, Xiangrui, 2017. "Design and experimental study of a small-sized organic Rankine cycle system under various cooling conditions," Energy, Elsevier, vol. 130(C), pages 236-245.
    4. Li, You-Rong & Du, Mei-Tang & Wu, Chun-Mei & Wu, Shuang-Ying & Liu, Chao & Xu, Jin-Liang, 2014. "Economical evaluation and optimization of subcritical organic Rankine cycle based on temperature matching analysis," Energy, Elsevier, vol. 68(C), pages 238-247.
    5. Lecompte, S. & Huisseune, H. & van den Broek, M. & De Paepe, M., 2015. "Methodical thermodynamic analysis and regression models of organic Rankine cycle architectures for waste heat recovery," Energy, Elsevier, vol. 87(C), pages 60-76.
    6. Meinel, Dominik & Wieland, Christoph & Spliethoff, Hartmut, 2014. "Economic comparison of ORC (Organic Rankine cycle) processes at different scales," Energy, Elsevier, vol. 74(C), pages 694-706.
    7. Eyidogan, Muharrem & Canka Kilic, Fatma & Kaya, Durmus & Coban, Volkan & Cagman, Selman, 2016. "Investigation of Organic Rankine Cycle (ORC) technologies in Turkey from the technical and economic point of view," Renewable and Sustainable Energy Reviews, Elsevier, vol. 58(C), pages 885-895.
    8. Tchanche, Bertrand F. & Lambrinos, Gr. & Frangoudakis, A. & Papadakis, G., 2011. "Low-grade heat conversion into power using organic Rankine cycles – A review of various applications," Renewable and Sustainable Energy Reviews, Elsevier, vol. 15(8), pages 3963-3979.
    9. Bao, Junjiang & Zhao, Li, 2013. "A review of working fluid and expander selections for organic Rankine cycle," Renewable and Sustainable Energy Reviews, Elsevier, vol. 24(C), pages 325-342.
    10. Nami, Hossein & Ertesvåg, Ivar S. & Agromayor, Roberto & Riboldi, Luca & Nord, Lars O., 2018. "Gas turbine exhaust gas heat recovery by organic Rankine cycles (ORC) for offshore combined heat and power applications - Energy and exergy analysis," Energy, Elsevier, vol. 165(PB), pages 1060-1071.
    11. Desai, Nishith B. & Bandyopadhyay, Santanu, 2009. "Process integration of organic Rankine cycle," Energy, Elsevier, vol. 34(10), pages 1674-1686.
    12. Lecompte, Steven & Huisseune, Henk & van den Broek, Martijn & Vanslambrouck, Bruno & De Paepe, Michel, 2015. "Review of organic Rankine cycle (ORC) architectures for waste heat recovery," Renewable and Sustainable Energy Reviews, Elsevier, vol. 47(C), pages 448-461.
    13. Cignitti, Stefano & Andreasen, Jesper G. & Haglind, Fredrik & Woodley, John M. & Abildskov, Jens, 2017. "Integrated working fluid-thermodynamic cycle design of organic Rankine cycle power systems for waste heat recovery," Applied Energy, Elsevier, vol. 203(C), pages 442-453.
    14. Wang, Jiangfeng & Dai, Yiping & Gao, Lin, 2009. "Exergy analyses and parametric optimizations for different cogeneration power plants in cement industry," Applied Energy, Elsevier, vol. 86(6), pages 941-948, June.
    15. F. Tchanche, Bertrand & Pétrissans, M. & Papadakis, G., 2014. "Heat resources and organic Rankine cycle machines," Renewable and Sustainable Energy Reviews, Elsevier, vol. 39(C), pages 1185-1199.
    16. Li, Gang, 2016. "Organic Rankine cycle performance evaluation and thermoeconomic assessment with various applications part I: Energy and exergy performance evaluation," Renewable and Sustainable Energy Reviews, Elsevier, vol. 53(C), pages 477-499.
    17. Li, Gang, 2016. "Organic Rankine cycle performance evaluation and thermoeconomic assessment with various applications part II: Economic assessment aspect," Renewable and Sustainable Energy Reviews, Elsevier, vol. 64(C), pages 490-505.
    18. Wang, Huarong & Xu, Jinliang & Yang, Xufei & Miao, Zheng & Yu, Chao, 2015. "Organic Rankine cycle saves energy and reduces gas emissions for cement production," Energy, Elsevier, vol. 86(C), pages 59-73.
    19. Li, Chengyu & Wang, Huaixin, 2016. "Power cycles for waste heat recovery from medium to high temperature flue gas sources – from a view of thermodynamic optimization," Applied Energy, Elsevier, vol. 180(C), pages 707-721.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Zhang, Xinxin & Zhang, Yin & Wang, Jingfu, 2020. "New classification of dry and isentropic working fluids and a method used to determine their optimal or worst condensation temperature used in Organic Rankine Cycle," Energy, Elsevier, vol. 201(C).
    2. Kang, Lixia & Tang, Jianping & Liu, Yongzhong, 2021. "Optimal design of organic Rankine cycle system for multi-source waste heat recovery involving multi-period operation," Energy, Elsevier, vol. 235(C).
    3. Li, Xiaoya & Xu, Bin & Tian, Hua & Shu, Gequn, 2021. "Towards a novel holistic design of organic Rankine cycle (ORC) systems operating under heat source fluctuations and intermittency," Renewable and Sustainable Energy Reviews, Elsevier, vol. 147(C).
    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).
    5. Ping, Xu & Yang, Fubin & Zhang, Hongguang & Xing, Chengda & Zhang, Wujie & Wang, Yan & Yao, Baofeng, 2023. "Dynamic response assessment and multi-objective optimization of organic Rankine cycle (ORC) under vehicle driving cycle conditions," Energy, Elsevier, vol. 263(PA).
    6. Aridi, Rima & Faraj, Jalal & Ali, Samer & Lemenand, Thierry & khaled, Mahmoud, 2022. "A comprehensive review on hybrid heat recovery systems: Classifications, applications, pros and cons, and new systems," Renewable and Sustainable Energy Reviews, Elsevier, vol. 167(C).
    7. 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).
    8. 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.
    9. 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).
    10. 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).
    11. 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).
    12. 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.
    13. 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).
    14. 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).
    15. 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).

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Bamorovat Abadi, Gholamreza & Kim, Kyung Chun, 2017. "Investigation of organic Rankine cycles with zeotropic mixtures as a working fluid: Advantages and issues," Renewable and Sustainable Energy Reviews, Elsevier, vol. 73(C), pages 1000-1013.
    2. Chintala, Venkateswarlu & Kumar, Suresh & Pandey, Jitendra K., 2018. "A technical review on waste heat recovery from compression ignition engines using organic Rankine cycle," Renewable and Sustainable Energy Reviews, Elsevier, vol. 81(P1), pages 493-509.
    3. Kermani, Maziar & Wallerand, Anna S. & Kantor, Ivan D. & Maréchal, François, 2018. "Generic superstructure synthesis of organic Rankine cycles for waste heat recovery in industrial processes," Applied Energy, Elsevier, vol. 212(C), pages 1203-1225.
    4. Li, Jian & Ge, Zhong & Duan, Yuanyuan & Yang, Zhen & Liu, Qiang, 2018. "Parametric optimization and thermodynamic performance comparison of single-pressure and dual-pressure evaporation organic Rankine cycles," Applied Energy, Elsevier, vol. 217(C), pages 409-421.
    5. Eyerer, Sebastian & Dawo, Fabian & Wieland, Christoph & Spliethoff, Hartmut, 2020. "Advanced ORC architecture for geothermal combined heat and power generation," Energy, Elsevier, vol. 205(C).
    6. Li, Jian & Ge, Zhong & Duan, Yuanyuan & Yang, Zhen, 2019. "Design and performance analyses for a novel organic Rankine cycle with supercritical-subcritical heat absorption process coupling," Applied Energy, Elsevier, vol. 235(C), pages 1400-1414.
    7. Li, Jian & Liu, Qiang & Ge, Zhong & Duan, Yuanyuan & Yang, Zhen & Di, Jiawei, 2017. "Optimized liquid-separated thermodynamic states for working fluids of organic Rankine cycles with liquid-separated condensation," Energy, Elsevier, vol. 141(C), pages 652-660.
    8. Eveloy, Valérie & Rodgers, Peter & Qiu, Linyue, 2016. "Performance investigation of a power, heating and seawater desalination poly-generation scheme in an off-shore oil field," Energy, Elsevier, vol. 98(C), pages 26-39.
    9. Imran, Muhammad & Usman, Muhammad & Park, Byung-Sik & Yang, Youngmin, 2016. "Comparative assessment of Organic Rankine Cycle integration for low temperature geothermal heat source applications," Energy, Elsevier, vol. 102(C), pages 473-490.
    10. Braimakis, Konstantinos & Karellas, Sotirios, 2017. "Integrated thermoeconomic optimization of standard and regenerative ORC for different heat source types and capacities," Energy, Elsevier, vol. 121(C), pages 570-598.
    11. Satanphol, K. & Pridasawas, W. & Suphanit, B., 2017. "A study on optimal composition of zeotropic working fluid in an Organic Rankine Cycle (ORC) for low grade heat recovery," Energy, Elsevier, vol. 123(C), pages 326-339.
    12. Lecompte, S. & Huisseune, H. & van den Broek, M. & De Paepe, M., 2015. "Methodical thermodynamic analysis and regression models of organic Rankine cycle architectures for waste heat recovery," Energy, Elsevier, vol. 87(C), pages 60-76.
    13. Li, Jian & Peng, Xiayao & Yang, Zhen & Hu, Shuozhuo & Duan, Yuanyuan, 2022. "Design, improvements and applications of dual-pressure evaporation organic Rankine cycles: A review," Applied Energy, Elsevier, vol. 311(C).
    14. Mondejar, M.E. & Andreasen, J.G. & Pierobon, L. & Larsen, U. & Thern, M. & Haglind, F., 2018. "A review of the use of organic Rankine cycle power systems for maritime applications," Renewable and Sustainable Energy Reviews, Elsevier, vol. 91(C), pages 126-151.
    15. Varma, G.V. Pradeep & Srinivas, T., 2017. "Power generation from low temperature heat recovery," Renewable and Sustainable Energy Reviews, Elsevier, vol. 75(C), pages 402-414.
    16. Sarkar, Jahar & Bhattacharyya, Souvik, 2015. "Potential of organic Rankine cycle technology in India: Working fluid selection and feasibility study," Energy, Elsevier, vol. 90(P2), pages 1618-1625.
    17. Zhang, Jianhua & Lin, Mingming & Fang, Fang & Xu, Jinliang & Li, Kang, 2016. "Gain scheduling control of waste heat energy conversion systems based on an LPV (linear parameter varying) model," Energy, Elsevier, vol. 107(C), pages 773-783.
    18. Wieland, Christoph & Meinel, Dominik & Eyerer, Sebastian & Spliethoff, Hartmut, 2016. "Innovative CHP concept for ORC and its benefit compared to conventional concepts," Applied Energy, Elsevier, vol. 183(C), pages 478-490.
    19. Li, Jian & Hu, Shuozhuo & Yang, Fubin & Duan, Yuanyuan & Yang, Zhen, 2019. "Thermo-economic performance evaluation of emerging liquid-separated condensation method in single-pressure and dual-pressure evaporation organic Rankine cycle systems," Applied Energy, Elsevier, vol. 256(C).
    20. Kyoung Hoon Kim, 2019. "Thermodynamic Performance and Optimization Analysis of a Modified Organic Flash Cycle for the Recovery of Low-Grade Heat," Energies, MDPI, vol. 12(3), pages 1-21, January.

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:rensus:v:114:y:2019:i:c:48. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/wps/find/journaldescription.cws_home/600126/description#description .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.