CONTACTS MARKET POTENTIAL STUDY FOR ORGANIC · PDF fileMARKET POTENTIAL STUDY FOR ORGANIC...

MARKET POTENTIAL STUDY FOR ORGANICRANKINE CYCLE TECHNOLOGY IN INDIAA Publication on Industrial Energy Efficiency

NEW DELHIIndo-German Energy Forum (IGEF)c/o Deutsche Gesellschaft fürInternationale Zusammenarbeit, (GIZ) GmbH,1st Floor, B-5/2, SafdarjungEnclaveNew Delhi – 110 029, India

T +91 11 4949 5353M [email protected] www.energyforum.in

CONTACTS

The IGEF Support Office can be reached at the following addresses:-

BERLINIndo-German Energy Forum (IGEF)c/o Deutsche Gesellschaft fürInternationale Zusammenarbeit, (GIZ) GmbH,Köthenerstraße 2, 10963 Berlin, Germany

T +49 30338424 462M [email protected] www.energyforum.in

BUREAU OF ENERGY EFFICIENCY


MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Publication on Industrial Energy Efficiency


CONSULTING PARTNER:- TECHNICAL PARTNERS:-

PUBLISHER:-

Indo-German Energy Forum Support Office (IGEF-SO),c/o Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH,B 5/1, Safdarjung Enclave, New Delhi – 110 029, India.

T : +91 11 49495353F : +91 11 49495391E : [email protected] : www.energyforum.in

CONSULTING PARTNER:-

BRIDGE TO INDIA Pvt. Ltd.N-117, Panchsheel Park, New Delhi - 110017

T : +91 11 46081579E : [email protected] : www.bridgetoindia.com Indiasolarmarket.com Indiasolarhomes.com

TECHNICAL PARTNERS:-

DURR CYPLAN Ltd.Carl Benz Str-34, 74321 Bietighetm Bissingen, Germany

T : +49 7142 78-55 2469 F : +49 7142 78-55 2469E : [email protected] : www.durr-cyplan.com

THERMAX INDIA Pvt. Ltd.D-13, MIDC Industrial Area, RDAGA Road, Chinchwada, Pune - 410019, INDIA

T : +91 20 6612 2100 +91 20 2747 5941 +91 20 2747 5942F : +91 20 2747 2049E : [email protected] : www.thermaxindia.com

Authors:-

Sandeep Goel, Bridge To India

Oliver Herzog, Bridge To India

Ankan Datta, IGEF Support Office

Dr. RR Sonde, Thermax India

Kiran Deshpande, Thermax India

Jochen Fink, Durr Cyplan Germany

Thomas Schumacher, Durr Cyplan Germany

June 2014

Disclaimer: The assumptions, views and opinions expressed in this publication are those of the authors themselves and/or the organisation to which they belong to or are affiliated with. They do not necessarily reflect the official policy or position of neither the Indo-German Energy Forum (IGEF) – Support Office and the Bureau of Energy Efficiency (BEE) of the Indian Ministry of Power (MOP), nor that of any other contributor to this publication. Any person relying on any of the information contained in this publication or making any use of the information contained herein, shall do so at its own risk. The Indo-German Energy Forum (IGEF) – Support Office, the Bureau of Energy Efficiency (BEE) of the Indian Ministry of Power (MOP) and all other authors or contributors to this publication hereby disclaim any liability and shall not be held liable for any damages including, without limitation, direct, indirect or consequential damages including loss of revenue, loss of profit, loss of opportunity or other loss of any kind.

Cover Images:-

On the cover page - (from left to right)

The Heber Second Imperial Geothermal Power Plant in Heber, California (Photo by Warren Gretz/NREL, NREL No. 00447)

The Leathers geothermal power plant is located in the Salton Sea, California (Photo by Warren Gretz/NREL, NREL No. 00416)

Diamond Shamrock refinery (previously Total Refinery) in Commerce City, Colorado. (Photo by David Parsons/NREL, NREL No. 05046)

On the back page -

Picture of the India Gate in New Delhi, India (left) and the Brandenburg Gate in Berlin, Germany (right)(Photo by Ajitha Vijayan, IGEF Support Office and by Ankan Datta, IGEF Support Office)


ExEcutivE summary

i

Energy is a critical input in any industrial process, and thus directly determines to a large extent, the environmental impact of the manufacturing process and the products of a any company. Most of the production processes involve heat energy that is generally produced by burning fossil fuels, as prime source of energy. Such production processes are inherently energy inefficient, thereby losing a significant amount of heat to equipment inefficiencies. This study focuses on waste heat recovery, especially the application of Organic Rankine Cycle (ORC) technology in the industrial sector in India.

ORC is a technology that operates similarly as the Steam Rankine cycle, except that the former uses an organic working fluid instead of steam. This organic working fluid has a lower boiling point and a higher vapour pressure than water, and is, thus able to use low temperature heat sources to run a turbine for power generation.

ORC technology, although new to India, finds some very successful installations in the country. There are a few installations in India based on this technology, notably a 4 MW waste heat recovery plant by UltraTech Cements in Andhra Pradesh, India1 and the 125 KW system installed in Pune by Thermax India Ltd. and the Department of Science and Technology of the Government of India. The latter installation uses the steam generated from solar parabolic troughs during the sunny days, in hybrid mode with biomass boiler during low radiation hours. There are two more installations by Thermax Limited, only for experimentation and research purposes - one in house installation since 2010 and the other supplied to IISc, Bangalore to be commissioned at their new campus.

The reasons for such low penetration of this technology in India are the low overall conversion efficiency of the system to convert the heat from external source to electricity (owing to low waste heat source temperatures), the high system cost, the lack of indigenous manufacturing capability and the lack of proper incentives. In addition, most opportunities for the deployment of the technology exists currently for waste to heat recovery than for stationary applications that use biomass or geothermal energy directly. This is because both biomass (except bagasse based systems) and geothermal energy are not as popular

1 The Waste heat recovery project installed at Saint Gobain glass manufacturing facility in Tamil Nadu uses the Steam Rankine cycle technology.

in India as solar or wind energy. In the solar thermal installations, as a technology that is gaining a solid foot in the Indian energy scenario, ORC can be used to exploit the medium to low temperature steam to generate electricity. Bagasse based cogeneration systems that are quite common in India, also have a promising future for ORC installations in India.

In India, there are many industries, as mentioned below, where the low temperature heat is expelled in the atmosphere without putting it to any practical use. On the other hand, the ORC technology has been commercially utilized in these sectors, especially in the developed world, to extract this “waste” heat.

y Industrial waste heat recovery applications (Iron and Steel, Cement and Glass)

y Internal combustion engines (ICE) and gas turbines

y Renewable energy power plants (solar thermal, biomass and geothermal)

y Heat recovery from high temperature heater exhaust used in process such as textile, edible oil refineries, etc.”

The total potential of electricity generation from ORC technology in India, including all the sectors, has been assessed during this study to be roughly around 4.4 GW by 2017. This potential is around 574 MW in the Iron and Steel industry, 35 MW in the Glass industry, 148 MW in the Cement industry, 1.4 GW in the solar thermal industry and 2.4 GW in the Biomass industry all till 2017. The potential of using this technology is not considered in the internal combustion engines and the gas turbines, both of which are used for captive power generation as there is no reliable aggregate data for such installations in India, and thus, a detailed sector wise industry analysis is required to explore further it. Unless the total potential of geothermal energy is assessed, the potential for ORC applications in this sector cannot be determined. Also the Indian biomass sector that although has still to go a long way, holds a promising future for stationary ORC applications, but currently the absence of detailed data on this sector, makes such an assessment impossible. It must be noted, as mentioned earlier, that this biomass sector excludes the bagasse based electricity generation and the cogeneration units. It is needless to mention here that if a quarter of this total potential is realised, then the capital cost and the climate impact of building several new thermal power units can be avoided apart from

ii


mitigating the fear instilled by the ever increasing fossil fuel prices.

From a broad industry analysis, it can thus be concluded that the potential for ORC technology is significant in the industrial and renewable energy sectors in India, but a detailed sector-wise analysis is needed in order to determine the exact potential of this technology accurately.

There are some technology providers in India for ORC technology that include both Indian as well as the multi-national companies, however the majority of the foreign companies who specialise in this technology, are yet to begin their work in India. Different business models, such as the ESCO, RESCO, captive power plants, third party sale of power, sale of power to the DISCOMs etc., are making the mass scale adoption of many such new technologies easy and commercially viable. In addition, policy and

financial incentives are also available in India, such as the NMEEE, SECF, NCEF etc., but further analysis is needed to find out how they would be applied for energy efficiency measures involving ORC systems. Proper institutional set-up in India to promote such energy efficiency initiatives (such as the BEE) and the recent focus on off-grid power generation, can also help proliferate the deployment of this technology that not only contributes to the energy security of the country, but also helps mitigate the climate impact by reducing the carbon emissions, apart from mitigating the need for new investments to build captive power plants that may be fossil fuel based.

Please note that the images in this document are from those industries in which the ORC technology can be widely implemented, and are, thus, chosen accordingly to give the reader an idea about the several opportunities to save waste heat for conversion to electrivity rather than being wasted.

Wheelabrator Shasta Energy Company, Anderson, California (Photo by Warren Gretz / NREL , NREL No. 00071)


contEnts

v

Executive summary i

1. Power generation through waste heat recovery 1

2. organic rankine cycle - technical details 5

3. Applicability and industry clustering 9

4. Market potential for ORC technology 15

5. Regulatory Support for Waste Heat Recovery Technologies 25

6. Waste heat recovery project at Saint Gobain Glass Manufacturing Facility 29

7. Indian Industry on ORC: Approach paper and Case Study by Thermax India Limited 31

8. German Industry on ORC: Approach paper and Case Study by DÜRR Cyplan Ltd. 39

9. Challenges for waste heat recovery projects in India and the way forward 43

Annexure: List of waste heat recovery projects used for power generation registered under the clean development mechanism in India 45

vi


aBBrEviations

BEE Bureau of Energy Efficiency

CDM Clean Development Mechanism

CER Certified Emission Reduction

CMA Cement Manufacturers Association

CSE Centre for Science and Environment

CSP Concentrated Solar Power

DC Designated Consumers

DRI Direct Reduced Iron

EC Energy Conservation Act

ECX European Climate Exchange

EEFP Energy Efficiency Financing Platform

EEX European Energy Exchange

ESCert Energy Saving Certificate

FEEED Framework for Energy Efficiency Economic Development

HFO Heavy Fuel Oil

ICE Internal Combustion Engine

IEX Indian Energy Exchange

JNNSM Jawaharlal Nehru National Solar Mission

MNRE Ministry of New and Renewable Energy

MOP Ministry of Power

MTEE Market Transformation for Energy Efficiency

NAPCC National Action Plane on Climate Change

NCEF National Clean Energy Fund

NEIIP North-Eastern Industrial and Investment Promotion Policy

NMEEE National Mission for Enhanced Energy Efficiency

ORC Organic Rankine Cycle

PAT Perform, Achieve and Trade

PXIL Power Exchange India Limited

RPO Renewable Purchase obligation

SECF State Energy Conservation Fund

SGGI Saint Gobain Glass India Limited

SRC Steam Rankine Cycle

UNFCCC United Nations Framework Convention on Climate Change

WHR Waste Heat Recovery

vii

list of figurEs

Figure 1: Schematic of Steam Rankine Cycle 2

Figure 2 : Schematic of Organic Rankine Cycle (Source: BOSCH) 3

Figure 3: Choice of technology for different waste heat source temperature 10

Figure 4: Estimating potential of power generation using ORC 10

Figure 5: Schematic of power generation from Clinker cooler heat source (Source: UltraTech Cement) 11

Figure 6: State-wise cement production capacity in India as on 31st March 2011 17

Figure 7: Production capacity of Cement industry in India 17

Figure 8: Cumulative potential of ORC technology in glass industry in India 18

Figure 9: Projected glass production in India 19

Figure 10: Cumulative potential of ORC technology in glass industry in India 19

Figure 11: Production capacity of Iron and Steel industry in India 20

Figure 12: Cumulative potential of ORC technology in Iron and Steel industry in India 20

Figure 13: Cumulative capacity additions projected for Biomass power in India 21

Figure 14: Cumulative potential of ORC technology in Biomass industry in India 21

Figure 15: Cumulative capacity additions projected for solar thermal power in India 22

Figure 16: Cumulative potential of ORC technology in solar thermal industry in India 23

Figure 17: Share of ORC potential in different industry sectors 24

Figure 18: Trend Analysis of CER prices between 2010 and 2012 (Source: ICE (www.theice.com) 36

Figure 19: Policy level intervention needed for making this waste to power a reality in India 35

Figure 20: Expected time lines and time till boosts from policy and regulatory support required 36

Figure 21: ORC in Shive Solar Biomass Power plant set up by THERMAX with support from DST for distributed power generation 38

Figure 22: ORC Plant by Thermax installed at IISC Bangalore for research and academic purposes 38

Figure 23: ORC system in Groß-Gerau 40

Figure 24: The flow chart schematically shows the system integration after the ORC expansion 41

Figure 25: Improvement of the power to heat ratio of a similar CHP unit with 834 kWe and 904 kWth 42

viii


list of taBlEs

Table 1: Non-exhaustive list of the main ORC manufacturers 13

Table 2: Summary of applicability of ORC in the cement, steel and glass industry 16

Table 3: List of WHR projects in Cement industry registered 18

Table 4: Key features and worldwide installed capacity of solar thermal technologies 22

Table 5: Total ORC potential in different applications in India (MW) 24

Table 6: Cycle 1 targets under the PAT scheme 27

Table 7: Funds disbursed by the BEE under the SECF 28

Table 8: Technical parameters of the WHR at SGGI 30


PowEr gEnEration through wastE hEat

rEcovEry

2


Heat losses arise both from equipment inefficiencies and from thermodynamic limitations of equipment and processes2. Heat is generated by fuel combustion or by chemical reaction in a process in which part of the heat generated is used up, and the rest of the heat is “dumped” into the environment by means of an exhaust gas or steam. Although the total energy lost in waste gases/steam cannot be fully recovered3, much of the heat could be recovered and be used for various useful and economic purposes. This would not only increase the efficiency of the process, but also reduce the fuel consumption, thereby reducing both the running costs and the carbon intensity of the process.

Waste heat can be utilized in two forms – utilising the waste heat in thermal applications or converting the waste heat in to electrical energy. Since the conversion of waste heat in to electricity involves efficiency losses at each stage, it is preferred to use the waste heat directly in thermal applications wherever possible, since the latter have comparatively lesser heat losses. In cases where this option is not viable, the waste heat is converted in to electricity. This electricity generated is either consumed within the process or is transferred to the grid.

Generation of power from waste heat typically involves the conversion of the (otherwise) waste heat to mechanical energy to drive an electric generator. Industries have different processes which in some way or the other involve dumping of heat into the atmosphere in the form of flue gases, hot water, steam etc. Heat can be recovered from these streams and utilized through different thermodynamic cycles to generate power. The most frequently used system for power generation from waste heat involves using the heat to generate steam to drive a steam turbine, a process commonly referred to as the Rankine Cycle, a schematic diagram of which is shown below in Figure 1.

2 U.S. DOE Energy Efficiency and Renewable Energy, Waste Heat Recovery: Technology and Opportunities in U.S. Industry http://www1.eere.energy.gov/manufacturing/intensiveprocesses/pdfs/waste_heat_recovery.pdf3 Express India, MEDA Plans to Popularise Waste Heat Recovery Schemes in Industries, January 2008 http://www.expressindia.com/latest-news/meda-plans-to-popularise-waste-heat-recovery-schemes-in-industries/263715/

The traditional Steam Rankine Cycle (SRC) has been one the most efficient options for waste heat recovery from exhaust streams with temperatures above 650-700°F [340-370°C]. At lower waste heat temperatures, this cycle becomes less cost effective because of the following reasons:

y Low pressure steam generated from low temperature waste heat requires larger, bulkier and costlier equipment.

y Low temperature waste heat does not provide sufficient energy to superheat the steam, which causes steam to condense resulting in the erosion of the turbine blades and other metallic units.

For such low temperature waste heat recovery applications, a better technology that may be used is the Organic Rankine Cycle since this cycle uses organic fluids that not only have lower boiling point temperatures than steam has, but also do not corrode the metallic parts of the equipment.

the organic rankine cycle (orc) is similar in operation to the steam Rankine cycle, except the fact that the former uses an organic working fluid while the latter uses steam. Typical working fluids include (but not limited to) silicon oil, propane, haloalkanes (e.g. “freons” or hydrofluorocarbons), isopentane, isobutane, toluene etc., that have a lower boiling points and higher vapour pressures than water or steam have. This allows the cycle to operate at significantly lower temperatures — sometimes as low as 150ºF [66ºC] – a general characteristic of many waste heat streams.

In comparison to water/steam that are used in the SRCs, the organic fluids used in ORCs have higher molecular masses enabling compact designs, higher

figure 1: schematic of steam rankine cycle

Waste heat from Process

Condenser

Evaporator

Pump

Exhaust

Electricity

GeneratorTurbine

3

mass flow rates, and higher turbine efficiencies (as high as 80-85%). However, since the cycle functions at lower temperatures, the overall efficiency is only around 10-20%, depending on the temperature of the condenser and evaporator. This overall efficiency of conversion of heat into electricity of ORCs (10%-20%) is lower than that of steam cycle (30%-40%) because the SRC operates at higher temperatures than the ORC. This lower efficiency is due to the limitation based on thermodynamic principle called the Carnot Theorem4.

Waste heat recovery through ORC systems can be applied to a variety of low to medium temperature

heat streams. An example of a recent successful installation in India is by UltraTech Cements India Ltd. in Andhra Pradesh, India, where the installed ORC plant recovers waste heat from the clinker cooler that has an exhaust gas temperature of about 6080F [3200C]. The ORC installation can generate 4 MW of power, thereby reducing CO2 emissions by approximately 16,871 tons per annum.

4 Carnot theorem: “No engine operating between two heat reservoirs can be more efficient than a Carnot engine operating between those same reservoirs”. The efficiency of a carnot engine is given by: Efficiency = (1-(TC/TH) Where TC is the temperature of cold reservoir in Kelvin (°K) and TH is the temperature of hot reservoir in Kelvin (°K). A Carnot engine operating with a heat source at 300ºF [150ºC or 423°K] and rejecting it at 77ºF [25ºC or 298°K] is only about 30% efficient. In this light, an efficiency of 10-20% is a substantial percentage of theoretical efficiency, especially in comparison to other low temperature options, such as piezoelectric generation, which are only 1% efficient.

advantages and disadvantages of orc technologies5,6

advantages y Large inlet temperatures ranging from 100°C or

lower to as high as 450°C;

y ORC modules are easy to install (compact, skid-mounted standard module) and very easy to operate;

y ORC systems require low maintenance (no droplet erosion in the turbine, low pressure evaporator, automation), thereby reducing the running costs

greatly, and need very little maintenance downtime (< 2% of the operational time per annum);

y System sizes range from a few kWe (down to 30kWe) to several MWe that make them perfectly suitable for tapping various thermal sources;

y For power capacities lower than 2 MWe, steam power plants are usually not well adapted since the operation and maintenance costs of the equivalent Steam Rankine Cycle are higher and the system efficiency is lower;

y Long working life of the system (20 years +) with very minimum maintenance needs. Most of the systems have very little or no turbine mechanical stress, while the closed leak proof systems

5 Enertime, World Engineer’s Convention, Waste Heat Recovery Projects Using organic Rankine Cycle Technology, September 2011 http://www.enertime.com/sites/www.enertime.com/files/documentation/whr_projects_using_orc_publication-for-world-engineers-convention.pdf6 Ormat Energy Converters, Proven Power From Cement Plant Waste Heat http://www.ormat.com/research/papers/test

figure 2 : schematic of organic rankine cycle (source: Bosch)

ORC ProcessPotential waste heat sources

Hot water cycle

Heat exchanger(vaporiser)

Feed pump Turbine

ORC cycle

Heat excharger(condenser)

Generator

Industry

Bioenergy

Solor energy

120-150 oc

Power feed to grid

G

4


prevent moisture from reaching the metallic turbine blades, thereby reducing the erosion levels to almost nil;

y The systems have very simple start up procedures coupled with automatic and continuous operation, which rules out the requirement of continuous operator attention;

y Simple treatment of water is enough for supply to the system, for which no expense is there on special water treatment;

y Since the organic compounds used have much higher molecular mass than water, the turbine blades rotate slowly resulting in a much lower vapour pressure of the system, which in turn results in much higher system stability.

Disadvantages y The biggest weakness of the technology is the

apparent low conversion efficiency of thermal energy into electricity (between 10% and 25%). The main reason of this low efficiency is the low operating temperature; but for the same operating temperatures, the SRC will not achieve any higher efficiency than the ORC given the thermodynamic limitations as explained above. However, the overall system efficiency can be increased to more than 95%, if the hot water (used to condense the hot organic fluid) in the heat exchanger can be used (for a variety of purposes such as for district heating or for cooling through vapour absorption machines or for cooking food or for preheating purposes or for various industrial purposes). It must be noted here that the temperature of this hot water is much lower than the heat stream on which the ORC system is running, but usable for other purposes.

y The use of certain organic fluids needs more stringent security measures compared to the steam cycle because of their higher flammability and, in some cases, toxicity compared to water or steam. However, given the large number of installations of varying sizes across the world, and the fact that the entire system is a closed system with very little or zero chances of leakage, the flammability or the toxicity issue can be deemed as quite negligible ones.

y Process plants of small production capacities do not find ORC technology much attractive, unless the cost of power from conventional supply systems is very high. For example, Cement plants having capacities lower than 3000 tons per day

capacity are unlikely to use ORC technology for power generation, unless the alternative cost of power from the normal power supply is extremely high.

y This technology is relatively new in India and there is only one manufacturer in the country. Import duties and custom duties may make this imported technology too expensive to be used in many of the industries, unless subsidies and tax holidays are provided to incentivise energy efficiency achieved.

y Since the technology is not yet in the mainstream unlike in Germany or other developed countries, there is also a need for large scale capacity building of the operators and maintenance technicians of the systems. Currently, the manufacturer of the equipment, if based out of India, would really find it difficult to provide after sales service if it imports and sells the systems in the country, which then would become a reason for many people to shy away from installing the systems for a fear of system breakdown.

Geothermal power plant close to El Centro, California (Photo by Warren Gretz / NREL , NREL No. 00442)


organic rankinE cyclE - tEchnical

DEtails

6


Development of the organic rankine cycle

Rankine Cycle is the process by which more than 80 percent of the world’s electricity is generated today. It is a thermodynamic cycle to convert heat energy into electricity, named after the Scottish engineer William John Macquorn Rankine who is regarded as one of the fathers of thermodynamic science for developing the theory of steam engine.

The Rankine Cycle system that uses water as a working fluid to take up external heat to run a steam turbine to generate electricity, is commonly referred to as the Steam Rankine Cycle or the SRC. The SRCs have been used for nearly a century or more now to generate electricity and would continue to be the main stream in the near foreseeable future. However, in 1883, when Frank Ofeldt developed an engine that boiled naphtha, rather than steam, to drive the pistons, it triggered the research into other organic fluids as the working fluid for power engines.

Later in the twentieth century, the Organic Rankine Cycle was developed using a variety of organic fluids such as the Hydrocarbons and the Hydrofluorocarbons or HFCs. The ORC systems are today mostly designed to extract heat from various renewable sources, such as the biomass and the geothermal sources, and for the recovery of low to medium temperature waste heat from a variety of industrial processes. However, with the solar thermal systems becoming more and more popular, the ORC systems find successful applications there as well.

The use of SRCs to recover high temperature waste heat for conversion into electricity is quite widespread, but the low temperature waste heat could not be recovered for long, except for minor uses such as minimal preheating. However, the way that ORC systems have evolved today, these low temperature waste heat sources are now getting prominence to add to the overall energy efficiency o f t he i ndustrial processes. In addition, power cuts that haunt many industries in India, would no longer pose much of a threat if such low temperature waste heat can be recovered to produce electricity since it reduces dependency on the electrical grids. In addition to this, it may help the usage of heat generated from low irradiation on solar thermal plants or from low calorific value biomass.

The concerns over the climate change impacts of electricity generation from fossil fuels, coupled with the rising prices of the latter, are fuelling the explosive growth of the installations of the ORC systems all over the world. In India, the huge focus on demand side energy efficiency to increase energy security and to mitigate the need for addition of electricity generation capacity through various regulations (such as the Energy Conservation Act 2001 and the NMEEE), institutions (such as the BEE), fiscal incentives (such as SECF and NCEF) and market mechanisms (such as the PAT scheme) would help fuel the market for the ORC systems in the future. In addition, the use of hydrocarbons over the hydrofluorocarbons (HFCs) in the ORC systems have resulted in further lowering the carbon footprint of the systems.

It must also be noted that in India, the rapid growth of the renewable energies has also resulted in the development of a biomass (bagasse based) and a solar thermal industry in the country, while it’s just a matter of a little time before biomass (other forms) and geothermal energies also develop hugely. Also the fact that the ORC based systems can be used with biomass cogeneration systems, makes ORC a very suitable technology for India, where there are many bagasse based cogeneration units. ORC systems find application in all of these renewable based industries, and thus, both the Indian and the German companies are already making efforts to commercialise the technology in the country. The case studies mentioned in the subsequent chapters help in strengthening this point.

system components

The major components of an ORC system are the following:-

y Heat exchangers (preheater, evaporator, cooling and condensing units)

y A regenerator (used mostly in waste heat recovery systems)

y An expander (mostly positive displacement systems such as scroll and screw expanders rather than turbo machines)

y A turbine

y A generator

y Ancillary systems include pumps, instrumentation and control systems, online control panel and an electricity feeder (to be connected to the electrical transmission system).

7

y System monitoring is done mostly through online software systems, and can be started/shut down easily through the online systems.

system operation

The ORC system operation is not only simple, but also almost identical to that of the SRCs. It can be explained briefly as below:-

y An external fluid (from which heat is to be recovered) provides heat either directly to the organic (working) fluid of the ORC system or to a thermal oil (that in turn heats the organic fluid) in

the preheater and the evaporator.

y The hot organic fluid then expands in the turbine converting the heat energy into mechanical energy. The generator in turn converts the mechanical energy into electrical energy.

y The hot organic vapour is then cooled in a heat exchanger by water (mostly) and then condensed. The water here gets heated in the process and can be used for various purposes as mentioned above to increase the overall system efficiency.

y The cool organic fluid is pumped back into the regenerator to close the cycle.

The Geysers power plant in California (Photo by David Parsons / NREL , NREL No. 01079)

A geothermal power facility near El Centro, California (Photo by Warren Gretz / NREL , NREL No. 00430)


aPPlicaBility anD inDustry

clustEring

10


ORC technology has been widely used all the world for nearly two decades or more, with more than 300 units installed having a total capacity of more than 2,000 MWe. These applications are not only for waste heat recovery, but also integrate various renewable applications, such as the biomass and the geothermal sources.

The applicability of ORC technology varies with the parameters of every energy source and needs to be customized for every installation. The major parameter that determines the choice of technology, is the temperature of the heat source, whether it is

waste heat or renewable energy. Figure 3 shows the applicability of different type of ORC technologies at different waste heat source temperatures. Typically, the Steam Rankine Cycles are used if the temperature of waste heat source is higher than 350°C.

An approximate potential of waste heat recovery through the Organic Rankine Cycle technology can be estimated by using a simple graph (Figure 4). The two parameters used for this estimation are the temperature (°C) of the waste gas and the mass flow rate (kg/s).

figure 3: choice of technology for different waste heat source temperature

Fluidstability limit

10 100 1000 10000

400

300

200

100

0

SMALL ORC HIGH

TEMPERTURE

TEMPERATURE TOO LOW

POW

ER T

OO L

OW

MAINSTREAM ORC

SOU

RCE

TEM

PER

ATU

RE

OC

LARGE ORCLOW

TEMPERATURE

Too many stagesHigh cost

OUTPUT kWe

STEAM

OTEC(Ocean Thermal Energy Congervation

MICR

O CO

GENE

RATIO

N

figure 4: Estimating potential of power generation using orc7

Porttage gas (kgs)0 2 4 6 8 10 12 14 16 18 20 22 24

750700650600550500450400350300250200150100

50

(kW)

24002200200018001600140012001000800600400Te

mpe

ratu

re(°

C)

11

Organic Rankine Cycle finds application in many different industrial sectors that may be categorized in to three major heads, namely:

y Industrial waste heat recovery

y Internal combustion engines (ICEs) and Gas turbines

y Renewable energy power plants

a. industrial waste heat recovery8

In industries, there are plenty of waste heat fluids of relatively low temperature that are dissipated to the environment, thereby wasting the thermal energy. Some of these heat sources are reused in other on-site applications (thermal applications) or are used for district heating (not popular in India though). Thus, when there is no direct application for this thermal waste heat, it could be used to generate electricity by means of an ORC.

One of the first commercial waste heat power generation plants using the Organic Rankine Cycle was implemented by TURBODEN using the exhaust gas from a Cupola Furnace in Torbole, Italy. During the same time period, another plant came up at

7 Heat recovery in Energy Intensive Industries, (HREII), Diagram for a preliminary estimation of the potential of ORC based heat recovery system, September 2010, http://www.hreii.eu/public/Diagram%20potentiality_ENG.pdf)8 ORCycle, Turn Waste Heat into Electricity by Using an Organic Rankine Cycle, April 2011 http://www.orcycle.be/publicaties_bestanden/Paper1_2nd%20ECP%20ORC_final.pdf

Heidelberg Cement in Lengfurt, Germany in 1998 by ORMAT TECHNOLOGIES, where the clinker cooler exhaust air at 270°C served as a heat input to an ORC system. After the successes of these installations, many industries all over the world have used ORC systems to convert their waste heat in to electrical energy. Some of these industries are Glass Plants, Thermal Oxidizers, Paint Ovens, Ovens, Brick Ovens, Cement Processing, Ore Processing, Petrochemicals etc.

A brief description of the applicability of ORC technology in the most promising sectors is provided below:

cement industry

Cement production process involves lime decarbonisation reactions, that being endothermic, require huge amounts of heat and high temperatures. The unused part of the heat supplied for these reactions can be found in the combustion gas – kiln gas – (after the raw material pre-heating) and in the clinker cooler air flow (an air stream used to cool down the clinker after it exits the kiln). The waste heat in these flows could, via thermal heat recovery circuits, be the heat sources feeding the ORC system for power generation purposes.

figure 5: schematic of power generation from clinker cooler heat source (source: ultratech cement)

Clinker CoolerHeat Source

Heat Boiler WasteHeat Recovery

ORC-EquipmentPower Generation

Air CondenserCooling - Process

Clinker CoolerWaste Gas

Waste gas

Thermal OilCircuit

Pentane - Circuit Cooling - Circuit

12


In India, typical cement production plants have production capacities ranging from 2,000 to 10,000 metric tonnes per day, with energy consumption ranging from 3.5 to 5 GJ per ton of clinker produced (of which 10%-15% is in the form of electricity).

As an indication, the power that can be produced by an ORC system in a typical cement making process can range from 0.5 to 1 MW per kiloton per day of clinker production capacity (assuming heat recovery is happening from both kiln and cooler waste flows). Using these figures, it can be estimated that the energy produced by an ORC can account for around 10%-20% of the total electricity demand by the cement plant.

iron and steel industry

In steel production and processing industries, there are multiple waste heat sources where energy recovery with the ORC is possible. Some of these sources include waste heat from rolling unit, forging unit, strip processing unit, heat treatment unit, blast furnaces, sinter, electric arc furnaces etc. The temperature range of exhaust gas from the reheating furnaces (typically between 350°C and 650°C) enables the use of thermal oil as a carrier for the organic heat transfer fluids used in ORC cycles.

While waste recovery from clean gaseous streams in the industry is common, heavily contaminated exhaust gases from coke ovens, blast furnaces, basic oxygen furnaces, and electric arc furnaces that are particularly used in this sector, continue to present a challenge for economic waste heat recovery.

glass industry

Installations of glass manufacturing are divided into two main types:

y Plants for producing flat glass

y Plants for producing hollow glass

Glass production involves melting and refining of the raw materials, a process that takes place at high temperatures requiring very high energy inputs. The unused heat supplied for glass production can be found in the combustion gas exiting the oven, and this gas can provide the required heat for the ORC system to generate electricity (via an intermediate thermal heat recovery circuit).

Glass production processes can vary depending on the kind of product (float or hollow glass) or the fuel employed (methane, etc.) or the raw materials used or the production capacities etc. This makes it difficult to develop a general rule of thumb to assess the quantity of power that may be produced by ORC systems through waste heat recovery. However, the exhaust gas temperatures are relatively high (400°C - 500°C), that may lead to high conversion efficiencies (up to 25%) for ORC systems, with related economic advantages.

b. internal combustion Engines (icE) and gas turbines9

Internal combustion (IC) engines and gas turbines typically have thermal efficiencies in the range of 20 to 50%. A large part of the energy produced by combustion of the fuel gets dissipated in the exhaust gases and jacket cooling. The exhaust gases often have a temperature level above 300°C, and thus, are suitable as heat input sources for ORC systems. Also the hot air used in the jacket for cooling having temperatures around 90°C, can also be used or integrated with an ORC system. In this manner, the total efficiency of the combined system (IC engine + ORC) can be substantially improved. Approximately 10% supplementary electric power can be generated from the same fuel input.

Another application of the Organic Rankine Cycle is to use the waste heat from the gas turbines installed in compressor stations for running huge compressors that in turn maintain the pressure of these gases flowing in the pipelines. By the end of 2009, within North America alone around 75.5 MW of waste heat recovery plants of such type were commissioned at different compressor stations.10

c. renewable energy power plants11

The ORC technology can be successfully integrated into renewable energy power plants, such as solar, geothermal and biomass fired units.

9 ORCycle, Turn Waste Heat into Electricity by Using an Organic Rankine Cycle, April 2011 http://www.orcycle.be/publicaties_bestanden/Paper1_2nd%20ECP%20ORC_final.pdf10 ICF International, Status of Waste Heat to Power Projects on Natural Gas Pipelines, November 200911 ORCycle, Turn Waste Heat into Electricity by Using an Organic Rankine Cycle, April 2011 http://www.orcycle.be/publicaties_bestanden/Paper1_2nd%20ECP%20ORC_final.pdf

13

In solar thermal plants, solar energy is being concentrated by parabolic troughs and used as an input heat source for a power cycle. The solar collectors can work at a temperature range of 300°C – 400°C. For a long time, this technology was linked to the traditional Steam Rankine Cycle for power generation. However, since the Steam Rankine Cycle needs higher temperature and a higher installed power in order to be profitable, the Organic Rankine Cycle that can work at much lower temperatures especially during periods of low solar radiation, offers a smaller equipment size and has good efficiency at such low temperatures. Utility scale solar thermal power plants is a well proven technology internationally. The parabolic dish, the solar tower and the parabolic trough are the three major technologies that are used to generate power in solar thermal technology.

Geothermal energy is widely available and offers a broad range of temperatures, and the ORC technology

is already applied for several decades to these heat sources. For low to medium temperature heat sources, the ORC is a favourable power generation cycle. This is a widespread application in Germany and in the rest of the developed world.

For biomass fired boilers, often an ORC i s preferred because of the lower operating pressure. The condenser heat can be used in (biomass) drier applications or for district heating.

A list of some of the most established companies in the market and their technology range is provided in Table 1. Among these players, ORMAT has supplied a 4.2 MW waste heat recovery system based on ORC technology to the UltraTech cement plant in Andhra Pradesh in India.

table 1: non-exhaustive list of the main orc manufacturers

manufacturer applications Power range heat source temperature

technology

ORMAT, US Geothermal, WHR, solar

200 kWe - 72 MWe 150°C - 300°C Fluid: n-pentane

Turboden, Italy CHP, geothermal 200 kWe - 2 MWe 100°C - 300°C Fluids: OMTS, Solkatherm Axial Turbines

Adoratec, Germany CHP 315 - 1600 kWe 300°C Fluid: OMTSGMK, Germany WHR,

Geothermal, CHP50 kWe - 2 MWe 120°C - 350°C 3000 rpm Multi-stage axial

turbines (KKK) Fluid: GL 160 (GMK) patented

Koehler-Ziegler, Germany

CHP 70 - 200 kWe 150°C - 270°C Fluid: Hydrocarbons Screw expander

UTC, US WHR, Geothermal 280 kWe > 93°CCryostar WHR, Geothermal n/a 100°C - 400°C Radial inflow turbine Fluids:

R245fa, R134aFreepower, UK WHR 6 kWe - 120 kWe 180°C - 225°CTri-o-gen, Netherlands WHR 160 kWe > 350°C Turbo - expanderElectratherm, US WHR 50 kWe > 93°C Twin screw expanderInfinity Turbine WHR 250 kWe > 80°C Fluid: R134a Radial

Turboexpander

Source: Open Repository and Bibliography, Technological and Economic Survey of Organic Rankine Cycle Systems http://orbi.ulg.ac.be/bitstream/2268/14609/1/ECEMEI_PaperULg_SQVL090916.pdf

McNeil Generating Station at Burlington - a biomass gasifier operating on wood chips (Photo by Warren Gretz / NREL , NREL No. 06356)


markEt PotEntial for orc tEchnology

16


As discussed in Section 2, ORC technologies find applications in three major industry categories, namely in waste heat recovery from industrial processes, in waste heat recovery from internal combustion engines and in renewable energy. This section provides an insight into such industries in India and thereby, provides an assessment of the energy that may be recovered and converted to electricity by ORC systems.

methodology used:

The current installed manufacturing capacity in every industry segment was determined. The future capacity additions till 2017 were projected using annual growth rates in the respective industry sectors. General thumb rules were determined for a typical size of the industry. An estimate of potential of ORC technology for waste heat recovery was calculated correlating

the manufacturing capacities and the possibility of an ORC installation in a typical industry.

a. market potential of orc in industrial processes

cement industry in india

The cement industry in India has seen a massive growth in the past decade. The total annual production of cement in India in 2010-11 was 174.29 million tonnes with Rajasthan leading the production with 30.92 million tonnes produced in 2010-11, followed by Andhra Pradesh with 29.44 million tonnes and Tamil Nadu with 20.63 million tonnes. The major cement producers in India are ACC (13% market share) followed by Ambuja Cement and Ultra cement with 10% market share each.

table 2: summary of applicability of orc in the cement, steel and glass industry

industry/application unit cement float glass steel: (rolling mill)

Heat source Kiln and clinker cooler gas

Oven exhaust gas

Preheating oven exhaust gas

Plant capacity Tons per day 2,500 500 6,000

Wasted thermal power in exhaust gasa MW 12.0 5.0 13.0

Thermal power to ORC MW 11.0 4.7 13.0

Thermal power to thermal users MW 1.0 0.3 -

Net ORC electric production MW 1.6 1.0 2.4

Net electricity productionb MWh/year 12,800 8,000 19,200

Avoided CO2 emissionsc Tons per year 9,664 5,520 12,096

Notes a - Assuming to cool down the gas to 150/160 °C b - Assuming 8000 operating hours/year c - Assuming 0.63 kg of CO2/kWh electric and 0.2 kg of CO2/kWh thermal (from CH4 combustion)

17

Projected cement Production

The Centre for Science and Environment (CSE), Delhi has projected the cement production growth in India at a CAGR of 7.7%. The data shows that cement production is likely to increase to 328 million MT by 2017. The industry has gone from being an energy intensive industry to one of the most energy efficient industries.

According to a study done by TURBODEN (one of the market leaders in ORC technology), a 2,500 ton per day plant of cement can be used to set up a 1.6 MW

12 CMA India (Cement Manufacturers’ Association of India)13 Centre for Science and Environment (CSE), Green Rating Project, 2009

waste heat recovery plant using the Organic Rankine Cycle. Based on this assumption and projected manufacturing capacity of cement industry in India, a rough potential of the electricity production from waste heat by ORC technology is estimated to be 574 MW. To strengthen this assessment, one must also note that there are 26 cement production plants in India registered under the CDM for their initiative to reduce carbon emissions resulting from their processes, with 5 projects registered under the CDM protocol for waste heat recovery for power generation.

figure 6: state-wise cement production capacity in india as on 31st march 201112

figure 7: Production capacity of cement industry in india

State-wise cement production capacity in India (2011)

Andhra Pradesh, 29.44

Tamil Nadu, 20.63

Maharashtra, 9.35

Madhya Pradesh, 19.19

Uttar Pradesh, 7.05

Orissa, 4.5

Karnataka, 9.78

Chhattisgarh, 8.63

Gujarat, 12.19

Rest of India, 15.17

Rajasthan, 30.92

Cement production capacity (Million tonnes per annum) in India

Mill

ion

tonn

es p

er a

nnum

2012-13 2013-14 2014-15 2015-16 2016-17

243.4262.1

282.3304.1

327.5

-

50.0

100.0

150.0

200.0

250.0

300.0

350.0

18


glass industry in india

With over 12% annual growth, and almost 12,000 TPD of installed capacity, the glass industry is an interesting and a high growth potential industry in India. More than a 100 years old now, with the first manufacturing plant being set up in 1908, this industry was classified as a cottage industry by the Indian government for a long time. However, with continuous surge in demand and a lack of capacity, the industry has seen steady growth even in times of economic downturn.

The glass industry comprises of four key segments: hollow glass (mostly containers), flat glass, fibres and special glass. Container glass is the largest segment that is witnessing strong demand from end user segments, such as liquor, beer, pharmaceuticals, food, cosmetics etc.

The total manufacturing capacity in India is currently 11,700 TPD with float glass having 4,700 TPD and container glass having 7,000 TPD.

Float glass has emerged as the preferred flat glass product accounting for 90 percent of total glass consumption and is growing at a CAGR of almost 12 percent. The demand for float glass is expected to grow at a CAGR of almost 12 to 15 percent over the next three to five years. The container glass industry has been growing at 8-10 percent consistently and is estimated at almost USD 1.1 billion.

Typically, a 500 ton per day glass manufacturing plant will have potential for a 1 MW Organic Rankine Cycle waste heat recovery plant. The projected waste heat recovery potential through ORC in the glass industry in India is depicted in Figure 13 with a total potential estimated at around 36 MW by 2017.

table 3: list of whr projects in cement industry registered

company whr capacity(mw)

location technology used Emission reduction(tco2 per annum)

Ultratech Cement 4 Andhra Pradesh ORC 16,871

Lanco Industries Limited

12 Andhra Pradesh SRC 78,380

KCP Limited 2.36 Andhra Pradesh SRC 7,766

India Cements 7.7 Andhra Pradesh SRC 51,527

JK Cement Works 13.2 Rajasthan SRC 70,796

ORC – Organic Rankine Cycle; SRC – Steam Rankine Cycle

figure 8: cumulative potential of orc technology in glass industry in india

Cumulative ORC potential for WHR (MW) in cement industry

Capa

city

in M

W

2012-13 2013-14 2014-15 2015-16 2016-17

426.8 459.6495.0

533.2574.2

-

100.0

200.0

300.0

400.0

500.0

600.0

700.0

19

iron and steel industry in india14

India is the fourth largest producer of crude steel and the largest producer of sponge iron or Direct Reduced Iron (DRI) in the world, and has one of the largest iron ore reserves in the world. As per the report of the Working Group on Steel for the 12th Five Year Plan of India, the sector is projected to grow at a rate of 11-12% annually.

The National Steel Policy 2005 had envisaged steel production to reach 110 million tonnes by 2019-20. However, based on the assessment of the current projects, both the greenfield and brownfield ones,

14 Myiris breport, Hindustan National Glass & Industries Ltd, May 4, 2012: http://breport.myiris.com/skp/HINNATGI_20120504.pdf

the Working Group on Steel for the 12th Plan has projected the crude steel production capacity in the county to go up to 140 million tonnes by 2016-1715.

Typically, a 6,000 ton per day steel rolling mill has a potential of generating 2.4 MW of electricity through an Organic Rankine Cycle waste heat recovery plant. The projected waste heat recovery potential through ORC in the Iron and Steel sector is depicted in Figure 15 at a total potential estimated to be around 148.4 MW by 2017.

15 Ministry of Steel, An overview of the steel sector, July 2012, http://steel.gov.in/overview.htm

figure 10: cumulative potential of orc technology in glass industry in india

Cumulative ORC potential for WHR (MW) in Glass industry

Mill

ion

tonn

es p

er a

nnum

2012-13 2013-14 2014-15 2015-16 2016-17

23.726.2

29.032.2

35.7

-5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

figure 9: Projected glass production in india

Projected glass production (Tons/day)

Glas

s pr

oduc

tion

(ton

s/da

y)

25000

20000

15000

10000

5000

02012-13 20113-14 2014-15 2015-16 2016-17

Float Glass Container Glass Total Production

20


figure 11: Production capacity of iron and steel industry in india

Iron and Steel production capacity (Million tonnes per annum) in India

Mill

ion

tonn

es p

er a

nnum

2012-13 2013-14 2014-15 2015-16 2016-17

86.196.4

108.0120.9

135.4

-

20.0

40.0

60.0

80.0

100.0

120.0

140.0

160.0

figure 12: cumulative potential of orc technology in iron and steel industry in india

Cumulative ORC potential for WHR (MW) Iron and Steel industry

Capa

city

in M

W

2012-13 2013-14 2014-15 2015-16 2016-17

94.3105.7

118.3132.5

148.4

-

20.0

40.0

60.0

80.0

100.0

120.0

140.0

160.0

b. market potential of orc technology in renewable energy

Biomass Potential in india

For an agriculture based economy, such as India, biomass is an important energy source given the benefits it offers. It is not only renewable, widely available, and carbon-neutral, but also has the potential to provide economic upliftment of rural areas by providing employment and access to clean

energy. Almost 32% of the total primary energy used in the country is derived from biomass in some way or the other, thereby making more than 70% of the country’s population dependent on it to meet their energy needs.

The current availability of biomass in India is estimated at about 500 million metric tonnes per annum. The Indian Ministry of New and Renewable Energy (MNRE) has estimated a surplus biomass availability of about 120 – 150 million metric tonnes per annum that includes agricultural and forestry residues. This capacity of biomass corresponds to a potential of about 18,000 MW of electricity generation through the ORC systems.

Apart from this, around 550 sugar mills in the

21

country can produce an additional 5000 MW power through bagasse based cogeneration, if they employ technically optimal cogeneration technology. Out of this potential, 3700 MW has been installed through Biomass combustion technologies, Non-bagasse cogeneration and biomass gasifiers.

ORC technology readily finds application in all the above said biomass technologies except biomass gasifiers that constitute about 4 % of the installed biomass power capacity in India.

solar thermal power generation potential in india

16 World Institute of Sustainable Energy, Achieving 12% Green Energy by 2017, June 2011 http://www.wisein.org/pdf/Final_12%25_RE_Report.pdf

Solar thermal power generation in India was limited to some pilot projects and lab scale research and development projects until the allocation of 500 MW of solar thermal power generation projects in the first phase of the Jawaharlal Nehru National Solar Mission (JNNSM). Concentrated solar power (CSP) or solar thermal technology also enjoys substantial allocation in the second phase of the national solar mission (2013-2017).

The mission targets to achieve 1000 MW of grid connected solar plant capacity by 2013, around 9,000 MW by 2017 (3,000 MW by allocation under the mission and 6,000 MW expected to come up due to RPO obligations) and 20,000 MW to be achieved by 202217.

17 MNRE National Solar Mission, Towards Building Solar India http://www.

figure 13: cumulative capacity additions projected for Biomass power in india16

Cumulative capacity additions in Biomass power (MW)

Capa

city

in M

W

2012-13 2013-14 2014-15 2015-16 2016-17

440

880

1,280

1,700

2,300

-

500.00

1,000.00

1,500.00

2,000.00

2,500.00

figure 14: cumulative potential of orc technology in Biomass industry in india

Cumulative ORC potential in Biomass sector (MW)

Capa

city

in M

W

2012-13 2013-14 2014-15 2015-16 2016-17

422

844

1,228

1,632

2,208

-

500.00

1,000.00

1,500.00

2,000.00

2,500.00

22


figure 15: cumulative capacity additions projected for solar thermal power in india18

Cumulative capacity additions in solar thermal (MW)

Capa

city

in M

W

2012-13 2013-14 2014-15 2015-16 2016-17

- -

500

1,000

1,500

-

200.00

400.00

600.00

800.00

1,000.00

1,200.00

1,400.00

1,600.00

There are different technologies which can be used to collect solar energy in the form of thermal energy (heat energy). Table 4 below gives a list of all the solar thermal technologies and the global installed capacity. It can be seen that Central Receiver Tower and the Parabolic Dishes cannot use the ORC technology. Thus only the Parabolic Trough and the Linear Fresnel technology are considered while estimating the potential of ORC in solar thermal

mnre.gov.in/file-manager/UserFiles/mission_document_JNNSM.pdf18 Assuming second phase announcement in end of 2012 and equal capacity additions in 2014-15, 2015-2016 and 2016-2017

energy.

Since 96% of worldwide installed capacity of solar thermal installations comprises of the Linear Fresnel technology and the Parabolic Troughs, it is assumed

19 Assuming second phase announcement in end of 2012 and equal capacity additions in 2014-15, 2015-2016 and 2016-2017

table 4: key features and worldwide installed capacity of solar thermal technologiestechnology annual solar

to electricity efficiency

Practical operating temperature

Power cycles considered

commercial maturity

worldwide installed capacity (mid 2010)

Linear Fresnel 8-10% 150-400°C Steam Rankine, Organic Rankine

Medium 8 MWe

Parabolic troughs 12-15% 150-400°C Steam Rankine, Organic Rankine

High 943 MWe

Central Receiver tower

20-30% 300-1200°C Steam Rankine, Brayton (Gas turbine)

Medium 38 MWe

Parabolic dishes 20-30% 300-1200°C Stirling Engine, Steam Rankine, Brayton (gas turbine)

Low 1.5 MWe

23

that the solar capacity in India will also come up in the same way.

geothermal power generation potential in india

Geothermal energy is the use of the earth’s inner heat to generate useful energy. It is a clean, renewable and indigenous source of energy.

India has the potential to produce 10,600 MW20 of power from geothermal energy, although there are no operational plants till now. Geological Survey of India conducted a study and has identified 400 medium to high enthalpy geothermal springs in India, clustered in seven provinces, namely The Himalaya, Sohana, Cambay, Son-Narmada-Tapi (SONATA), Bakreswar, the Barren Islands and Godavari province.

Geothermal energy can be used for both direct use and power generation. In India, the direct use of geothermal energy for various processes, such as drying, bathing and swimming, has been done on non-commercial basis till now.

As of now there are no capacity additions which are expected to come in geothermal energy in India in the next two to three years excepting the possibilities of pilot projects, hence the potential of ORC technology in this sector is not considered in this study.

20 IBC Conference Geothermal Power Asia 2000, Geothermal Resources of India, Feb 2000 http://www.geos.iitb.ac.in/geothermalindia/pubs/IBC/IBCTALKweb.htm

c. market potential of orc technology in internal combustion engines and gas turbines

Internal combustion engines and gas turbines typically have a thermal efficiency in the range of 20 to 50%. In India, apart from the combined cycle power plants, the gas turbines, the diesel generators and the gas engines are used on a large scale for both commercial and industrial purposes. Mostly this is used to generate power for captive consumption. A waste heat recovery technology would be economically feasible when utilized on a 24 x 7 hour basis, which may not be the case for most of these installations. In the commercial sector, many companies have installed vapour absorption machines to produce chilled water for air-conditioning using the waste heat coming out from gas turbines/engines. A more detailed analysis is required to estimate the potential of this sector with respect to ORC technology.

As of now, this sector is not considered in the estimation of overall potential of ORC technology.

figure 16: cumulative potential of orc technology in solar thermal industry in india

Cumulative ORC potential (MW) in solar thermal industry

Capa

city

in M

W

2012-13 2013-14 2014-15 2015-16 2016-17

- -

480

960

1,440

-

200.00

400.00

600.00

800.00

1,000.00

1,200.00

1,400.00

1,600.00

24


figure 17: share of orc potential in different industry sectors

d. summary of potential of orc technology

A snapshot of the potential of ORC applications in different industrial sectors is provided in Figure 21. The potential is based on estimated capacity additions in different industrial sectors explained in the section above.

Potential of ORC technology in major industry sectors in India (MW)

Cement

Glass

Iron and Steel

Solar Thermal Energy

Biomass Energy

table 5: total orc potential in different applications in india (mw)sector capacity (mw)1. Waste heat recovery in major industries

a. Cement 574.2

b. Glass 35.7

c. Iron and Steel 148.4

Total 758.3

2. Renewable energy

a Solar Thermal energya 1,440.0

b Biomass Energyb 2,208.0

c Geothermal Energyc -

Total 3,648.0

Grand Total 4,406.3d

a – 50:50 allocation is assumed for solar thermal and solar PV in second phase of JNSSMb – Capacity additions during 2012-2017 have been accountedc – There are no market developments in this sector in Indiad – The estimate is based on desk research and broad assumptions, more in-depth industry analysis needs to be carried out to come up with more realizable

potential


rEgulatory suPPort for wastE

hEat rEcovEry tEchnologiEs

26


history of waste heat recovery in india

The Clean Development Mechanism (CDM) was introduced during the Kyoto Protocol, signed on 11th December, 1997. The protocol was a binding obligation signed by member countries of the United Nations, under the United Nations Framework Convention on Climate Change (UNFCCC), and obliges the signatory countries to reduce their greenhouse gas emissions by 5.2% during the period 2008-2012 against the baseline emissions in the year of 1990. Projects registered under the CDM mechanism receive tradable Certified Emission Reduction (CER) credits for every tonne of Carbon-dioxide (CO2) equivalent emission reduced. India currently has more than 60 projects using waste heat recovery systems that are registered as CDM projects.

In India, the first waste heat recovery (WHR) project using Organic Rankine Cycles (ORC) that was registered with the CDM, was by Ultratech Cement, in March 2007. The project’s annual emission reduction was 16,871 tonnes of CO2-eq. The cement industry is traditionally known to be high on energy consumption and low on energy efficiency. The ORC at Ultratech Cement has a capacity of producing 4.8 MW of electricity and meets 10% of the power requirement of the cement plant. The cost of generation of

electricity is INR 0.20 (EUR 0.003). It also has high energy efficiency as it not only has no water or fuel requirements, but also uses the easily available organic fluid, iso-pentane, as the working fluid in the ORC system. This results in a saving of INR 80 million (EUR 1.2 million) every year on the cost of power generation.21 Thus the introduction of the ORC has not only made the production cycle more energy efficient, but also has also helped reduce the operational costs by reducing the energy costs. In addition to this, the company can trade the CERs issued to them to generate further revenues.

The five exchanges trading in carbon credits are the European Climate Exchange (ECX), NASDAQ OMX Commodities Europe, PowerNext, Commodity Exchange Bratislava and the European Energy Exchange (EEX). Figure 22 shows the fluctuations in the daily spot prices of the CER futures on the ECX between January 2010 and October 2012. The prices or CER futures has fallen steadily over the past years from a high of INR 889.2 (EUR 13.68) in January 2010 to a low of INR 145.60 (EUR 2.24) in October 2012 to less than INR 80 (EUR 1) as of December 2013. 22This rapid and sharp fall in prices from July 2011 raises questions regarding the relevance of the CERs in the future, and thus the CDM is no longer considered a functional incentive scheme. If the fall in prices of the CERs continues, industries will not be incentivised to reduce their emission reductions through CERs.

21 Ultratech Cement, Andhra Pradesh Cement Works http://www.ultratechcement.com/images/downloads/sustainability_resources_APCW.pdf22 European Energy Exchange, Emission Rights, CER Future, October 2012 www.eex.com/en/

figure 18: trend analysis of cEr prices between 2010 and 2012 (source: icE (www.theice.com)

Daily spot price trend of CER Futures on the ECX

Setting Price...20

15

10

5

0

Jan/

10

Mar

/10

May

/10

Jul/

10

Sep/

10

Nov

/10

Jan/

11

Mar

/11

May

/11

Jul/

11

Sep/

11

Nov

/11

Jan/

12

Mar

/12

May

/12

Jul/

12

Sep/

12

27

Present regulatory scenario and fiscal incentives for waste heat recovery

The National Action Plan on Climate Change (NAPCC) of India brought eight national missions in 2008 in order to reduce the effects of climate change in the country. The National Mission for Enhanced Energy Efficiency (NMEEE) is one amongst the eight missions of the NAPCC. The Government of India in 2002 set up the Bureau of Energy Efficiency (BEE)23 under the Energy Conservation Act (EC) of 2001. The BEE was set up to structure policies around promoting energy efficiency in the Indian economy. One of the primary mandates of the BEE is to regulate the NMEEE, along with the Ministry of Power (MOP).

The NMEEE has four constituent schemes, as shown below, of which the PAT scheme is the one applicable for the Waste Heat Recovery initiatives.

y the Perform, Achieve and Trade (PAT) scheme

y the Market Transformation for Energy Efficiency (MTEE) scheme

y the Energy Efficiency Financing Platform (EEFP)

y the Framework for Energy Efficiency Economic Development (FEEED)

Perform, achieve and trade: The EC Act has specified a list of Designated Consumers (DC) consisting of the aluminium, cement, chlor-alkali, fertilizer, pulp and paper, thermal power, iron and steel, and textiles industries. The EC act specified

23 Bureau of Energy Efficiency http://www.beeindia.in/

a targeted amount of energy reduction for these DCs between 2012 and 2015. The DCs will be issued Energy Saving Certificates (ESCerts) for every tonne of oil equivalent energy that they save over and above their respective targets. These ESCerts can then be traded on the Indian Energy Exchange (IEX) or on the Power Exchange India Limited (PXIL). DCs who have failed to achieve their targets, can avoid being penalized by purchasing ESCerts, amounting to the shortfall in their target achievement. The issuing of these certificates shall be reviewed on a case by case basis by the BEE or the MOP. The scheme, with its tradable energy certificates hopes to improve the cost effectiveness in promoting energy efficiency. The target for 2014-15 is to reduce energy consumption in the specified industries by 4% from the base year of 2009-10. Table 6 gives the targets under the scheme for cycle 1 (2012-2015) for every DC sector.

Since Waste Heat Recovery (WHR) finds application in most of the DC sectors, the DCs can reduce their annual consumption of energy and increase their energy efficiency by implementing such technologies.

other regulatory initiatives

The Cement Manufacturers Association (CMA) had petitioned the Government of India during its pre-budget meeting to include some incentives and subsidies to bring the cement industry in the country at par with the other core infrastructure industries.24 One of the core energy efficiency measures taken by cement manufacturing units is the waste heat

24 The Economic Times; Budget 2012: Levy uniform and specific rate of excise duty on cement says CMA; Feb 23rd 2012

table 6: cycle 1 targets under the Pat scheme

sector min. annual energy consumption for the Dc (toe)

no. of Dcs Energy saving targets under Pat between 2012-2015 (million toe)

Aluminium 7,500 10 0.456Cement 30,000 85 0.816Chlor-alkali 12,000 22 0.054Fertilizer 30,000 29 0.478Iron and steel 30,000 67 1.486Pulp and paper 30,000 31 0.119Textile 3,000 90 0.066Thermal power plant 30,000 144 2.211Total 478 6.682

Source: PAT, Ministry of Power 2012; BRIDGE TO INDIA analysis

28


recovery. But the initial costs of setting up a waste heat recovery system, especially an ORC, is between INR 81 million (EUR 1.2 million) and INR 108 million (EUR 1.7 million) per Mega Watt.25 This is almost at par with the capital expenditure involved in setting up a plant of similar capacity based on renewable sources of energy, such as wind, solar, biomass, or small-hydro. The CMA has petitioned the government to consider waste heat recovery as a part of renewable energy sources. Renewables currently receive incentives, that include preferential tariffs for sale of electricity generated, accelerated depreciation benefits, generation based incentives, capital subsidies, import duty exemptions, tax exemptions and research and development support amongst various others.

The Biomass Power and Cogeneration Programme of the Ministry of New and Renewable Energy (MNRE) have incentivised the usage of ORC systems in biomass and cogeneration plants. Any plant under this programme can avail of an 80% Accelerated Depreciation benefit on the purchase of the ORC systems, thereby reducing the high initial capital costs of setting up an ORC system.

As per the Power Minister of the state of Assam, Mr. Pradyut Bordoloi, the state is planning to formulate a policy that makes the inclusion of waste heat recovery systems compulsory in all coking coal factories. Assam currently has over 40 coking coal factories that not only have very high emission levels, but are also not contributing to emission reduction efforts. The industry can currently avail of all incentives

25 Energy Manager Training, Cogeneration of Power Utilising Waste Heat in Cement Manufacture: Technological Perspectives h t t p : / / w w w. e n e rg y m a n a g e r t r a i n i n g . c o m / J o u r n a l / 2 4 0 3 2 0 0 6 /CogenerationofPowerUtilisingWasteHeatinCementManufacture.pdf

under the North-Eastern Industrial and Investment Promotion Policy (NEIIP-2007) to implement such energy efficiency measures. If these factories fail to set up the waste heat recovery systems, they will be ineligible for all these incentives and will be put on a negative list under the NEIIP policy. The coking coal plants have high heat generation from the furnaces, and are therefore, ideally suited to adopt the waste heat recovery systems. However, if stringent penalty measures are not taken for non-compliance, then it might be difficult to bring energy efficiency measures into an industry that has so far has had no economic or regulatory incentive to promote them.

In 2010, the Ministry Of Power (MOP) of the Government of India set up the State Energy Conservation Fund (SECF) under section 16 of the EC Act of 2011. The total amount dedicated to this fund from 2010 to 2012 was INR 700 million (EUR 10.8 million). The funds are disbursed by the BEE. The initial disbursement carried out by the BEE was for a total of INR 173 million (EUR 2.7 million) during the financial year 2009-10. Table 7 gives the state wise breakup of the distributed funds. This initiative by the MOP encourages the adoption of energy efficiency methods at the state level, thus ensuring more targeted efforts.

table 7: funds disbursed by the BEE under the sEcf

state amount millions(inr) amount (Eur)Nagaland 12.5 1,92,308Haryana 20 3,07,692Punjab 20 3,07,692Rajasthan 20 3,07,692Kerala 20 3,07,692Andhra Pradesh 20 3,07,692Tamil Nadu 20 3,07,692Karnataka 20 3,07,692Chhattisgarh 20 3,07,692

Source: Ministry of Power, Govt. of India


wastE hEat rEcovEry ProjEcts at glass

manufacturing facilitiEs in inDia

30


Saint Gobain Glass India Limited (SGGI) is a 100% owned subsidiary of Compagnie de Saint-Gobain in France, the world’s largest manufacturer of flat glasses. It has an Indian manufacturing unit in Sriperumbudur district of Tamil Nadu. The plant manufactures various types of flat glass using the float glass manufacturing process. The plant houses two Float Lines, two automotive glass processing lines, a 5 million sq. metre mirror processing line and a coater facility, all of which are in a 175 acre facility.

The processes mentioned involve large amount of waste heat that was being expelled in the atmosphere. To curtail the environmental impact from its facility, SGGI has installed a waste heat recovery boiler in the flue gas stream to convert this heat into steam. This is the first and only kind of waste heat recovery system installation in the glass industry in India. This project is registered with the UNFCCC as a CDM project, and it helps to reduce about 7,800 tons of CO2 emissions from the atmosphere.

Out of the two float glass lines, the heat recovery boiler system is set up in float line no. 2 that has a

26 UNFCCC Project Design Document, Power generation from flue gas waste heat, Tamil Nadu, October 2012, http://cdm.unfccc.int/Projects/DB/TUEV-SUED1265724642.95/view

capacity of 800 tonnes per day. The waste heat emitted from the float line is used to generate steam, which in turn rotates the turbine, thus generating electricity.

Apart from the above described waste heat recovery project, another glass manufacturing company Asahi Glass India Ltd, has installed a waste heat recovery system to recover the heat available from the flue gas of the existing fuel oil fired Glass Furnace in its manufacturing facility situated in Maharashtra, India. The waste heat recovery plant is based on a steam rankine cycle and helps in reducing 10,408 tonnes of CO2 emissions from the facility27. This project is also registered with the UNFCCC as a CDM project.

Apart from the savings caused by the in-house electricity production, the only additional source of revenue to sustain these projects is the PAT scheme, especially since the CDM is quite non-functional. Following section describes the major challenges faced by the Indian industry to incorporate waste heat recovery systems in their operations.

27 UNFCCC Project Design Document, Fossil Fuel switch project at Asahi India Glass Ltd, Taloja, Maharashtra, India - http://cdm.unfccc.int/Projects/Validation/DB/J5LPBWBFNEM97CGET17WOGHH90BBTW/view.html

table 8: technical parameters of the whr at sggi26

Particulars DEtailsCapacity of the glass plant Float glass line 2: 800 tonnes/day

Type of technology Rankine cycle

Rated capacity of power plant 1.23 MW (captive use)

Exhaust gas quantity 87000 Nm3/hr

Exhaust gas inlet temperature to boiler 430°C

Exhaust gas outlet temperature 250°C

Steam quantity 7,600 kg/hr

Steam pressure 390°C

Average annual carbon emission reduction (tonnes of CO2e) 7,854

Cost of the Project INR 110 Million (EURO 1.69 million)

Start date of WHRB project 9th May 2007

Commissioning date of WHRB-TG system 30th January 2009


inDian inDustry on orc: aPProach PaPEr anD

casE stuDy By thErmax inDia limitED

32


introDuction

Waste Heat by definition is the ultimate heat rejected by any process in which options of all the heat that can be internally used, is exhausted, and any further use may not be economically viable. Waste heat emitted by the process is based on the optimization of resources and is, therefore, strongly dependent on economic parameters. The quantity and quality of waste-heat varies depending on the nature of the process and optimization algorithm used by the respective process licensees.

Waste heat can be effectively used as heating energy (steam) and for cooling (air-conditioning by vapour absorption) if there is a scope for such a usage. Effective utilization of waste heat for cooling and heating, although economically attractive, calls for proximity of user points that can utilize this energy. This becomes a bottle neck in many instances. Hence, the conversion of waste heat to electricity becomes one of the most suitable options in this space of waste heat to energy solutions. Electricity generation can be monitored, fed into the grid and also incentivized in a most rigorous manner. The major challenge, however, is the “technology” needed for conversion of waste heat to electricity. Waste heat at temperatures in excess of 450°C and in sufficiently high quantity (>15 million kcal/h or about 5 MWe) makes power generation from such waste-heat system economically viable. This is due to the fact that such conversion systems have their replica in the fossil based power plants using Steam Rankine Cycle (SRC). SRC having proliferated itself as viable heat to power generating option can, therefore, be used in waste heat to electricity applications when the quality of waste heat matches close to the fossil energy systems or the quantity is enough for generating electricity in excess of 10 MW scale.

The major challenge, thus, lies when the waste heat quality and quantity becomes lower than what is stated above – let’s call it as medium waste heat systems – and this medium waste heat is the most typical waste heat which needs a different approach. This is given in the following sections.

challEngEs in thE mEDium wastE to hEat PowEr gEnEration systEms

True challenges of waste-heat become more evident when the temperature levels go below 450°C and/or quantity of the waste heat falls below 10 million kcal/h. The most obvious challenge is due to the lower efficiency of energy conversion devices at lower temperature levels coupled with high cost of heat recovery at such low temperatures. Besides this, the power generation systems for such medium waste heat streams pose limitations in the design and manufacturing of the prime movers and, hence, result in high cost. Therefore finding an economically viable solution for such waste heat to power generation system requires, a multiple approach both at technological level as well as at the policy level. Fortunately the technological advances in the new power cycles have made it viable to explore alternate options in this segment of the waste heat to electricity.

There is yet another segment of waste heat which is emitted at lower than 100°C and this requires a different treatment. This is kept out of the scope of the current ambit. It can be safely assumed that 90% of waste heat belongs to the medium category, i.e. less than 300°C and/or about 10 million kcal/h. Merely extrapolating the conventional solution available at the high temperature and high quality will not address this situation, since most of the waste-heat coming from the processes is in this range, and in this range the conventional solutions are not optimal solutions. Hence, the need of the hour is to address this segment with complete focus and concentration, since any solution in this segment will impact large number of industrial processes from small scale to large scale enterprises. This will also result in saving of substantial quantity of fossil fuels that are playing havoc in the Indian economy due to the current account deficit issues mainly due to the increased cost of crude oil import.

issuEs rElating to thE ExtraPolation of solution using stEam turBinE BasED systEms

Steam turbines are intrinsically designed for high power capacity. There is a fundamental aero dynamic basis for this. The cost per kW of steam turbine is highly functional of the MW rating of the turbine due to the design limitations of the steam turbines for lower capacity systems. To give an example, a 10 MW range turbo-generator costs about INR 7,500 per kW

33

(approximately INR 7.5 million per MW). However, the turbo-generators at 1 MW scale cost about INR 35,000 per kW or INR 35 million per MW, and the cost goes up exponentially over INR 100,000 per kW or INR 100 million per MW at 50 kW scale. The reason for this is both technological as well as of economy of scale. A turbo generator that costs INR 35 million per MW, when coupled with waste heat recovery systems and rest of the plant, results in the cost of power per MW in excess of INR 60 million that is the upper bound in the viability scale of waste heat to power solutions. Below 1 MW scale, the numbers become much more challenging and hence feasibility is practically impossible.

Steam turbines and waste-heat systems are fairly matured in terms of technological development and, thus, further scope of reduction in cost is rather limited. Hence, the only feasible solution is to move away from the steam cycle and to explore the alternate options.

what is ProPosED

Clearly, for this range of waste-heat, a steam based solution would not solve the problem. Alternate power cycles that are optimum for this temperature and capacity, need to be given a thrust to make waste heat to power attractive not only from an efficiency point of view, but also from a financial one. A very fundamental level analysis indicates that moving away from the SRC to other Rankine Cycles, such as the Organic Rankine Cycle and/or the Organic Based Hybrid Cycles (Rankine plus Brayton), would bring feasibility in this range over a period of time. Further, these cycles enable higher system efficiency and more compact equipment. The shift from steam based cycles to other fluids based cycles implies the use of fluids of lower density resulting in much lower equipment size at lower operational temperature ranges. The direct consequence of this is the usage of lower material content per kW of power generated. Ideally a 300°C flue gas generating 1 MW power through a steam cycle would use, say, 25 kg of steam per kW while an equivalent Organic Rankine cycle would use less than 4 kg per kW. Therefore, there is a strong basis for the shift. Besides this, design based on screw expanders or even on simple internal combustion engines, greatly reduce the cost of the equipment. Further these cycles present themselves to multiple level innovations and offer themselves to much higher efficiency possibilities. One more

advantage in these advanced cycles is the lower water consumption, and these cycles can be coupled with vapour absorption cooling systems as well to make them water free without any compromise on the efficiency due to the air cooled systems. Such power plants based on organic fluids will be the most attractive option that needs to be explored seriously in India.

othEr innovativE solutions in wastE to PowEr systEms

Another major component in the waste heat to power scenario is heat recovery devices. Currently these heat recovery devices are designed in a very conventional manner using standard materials. Due to low pressures, there is a high potential to use much lighter weight materials, and also need to be investigated thoroughly to reduce material content, and hence, the costs. This, though may look trivial, calls for a different approach in developing waste heat exchanger designs using thinner tubes and advanced heat transfer extended surfaces that enhance the waste heat transfer to the secondary fluids.

nEw moDEl rEQuirED for fastEr ProlifEration of wastE hEat to PowEr tEchnology in inDia

The above discussions indicate that the for waste-heat to power recovery based on steam cycles, will not yield the desired results, and hence new cycles mentioned above with appropriate cost reduction measures for the waste heat recovery devices, must be developed. These devices can generate electricity from waste heat sources of temperatures 350°C to as low as 140°C, and have capacities ranging from 1 to 3 MW scale to 50 kW scale. These systems can be then used in not only waste-heat recovery to power conversion from the currently identified sectors, such as Cement, Steel, Fertilizers, Glass and Aluminium, but also can be used in many applications in small to medium scale sectors as well. So much so that such development can become ubiquitous, and hence can be multiplied on a large scale in India. This is the only way that waste heat to power systems can proliferate in India.

34


It may be worthwhile to mention that when screw compressors for air-conditioning purposes were introduced, there were reservations of accepting the alternate option mainly due to very high capital costs. However, as the technology became popular and the number of installations multiplied, the costs have drastically come down, and today more than 90% of the compressors used in the air-conditioning industry are based on screw compressor technology. Fundamentally, screw compressor technology is superior to the conventional reciprocating by its very nature. There is a similarity between this and the proposed Organic Rankine Cycle based screw expander development that is one of the critical components in this new waste heat to power technology domain.

One more analogy that can be given is that of the diesel engines which are sold in large numbers both in MW and in kW capacity ranges. Cost per kW of diesel engine varies within 20% range between kW range and MW range. Clearly this is because of the market proliferation, and hence the resultant cost optimization. In a similar way, the Organic Rankine Cycle and the Hybrid Cycles would also become popular due to their intrinsic lower material content and are sure to become cheaper than the conventional steam turbines in the near future. Also the cost per kW would remain almost in the same range both in kW and in MW capacities.

The new technology for waste heat to power conversion would, therefore, be based on the advanced Organic Rankine or Hybrid Cycles using the improved waste heat recovery exchangers and new cycles integrated with systems that use less water in the power cycle. The ranges can be at 1000 kW, 300 kW and 50 kW scales with target parameters on cost, space, water consumption and availability factors. These can be bench marked, and all the developments must shoot to reach the target values in a time bound manner.

Policy lEvEl intErvEntion nEEDED for making wastE to PowEr a rEality in inDia

Waste heat to power is restricted to only the industrial segment in the Indian market, and hence needs different instruments for proliferation in the country. There is a need for an India centric technology

development while inspiration can be taken from what is happening in the other parts of the world.

The strategy, therefore, should be multipronged. Like in many instances of introduction of new technologies – be it solar or wind energy, where the state invested in the early development phase to trigger the further proliferation using many instruments at its command – the waste heat to power also calls for similar developments to be carried out. An initial phase of development is needed when technology demonstration needs to be carried out based on a dedicated research and development as well as pilot scale demonstration units followed by initial deployment based strategies.

The first and foremost step needed is, therefore, demonstration of this new concept in a number of facilities where such concepts are well suited for demonstration. One can choose to demonstrate at 50 kW scale, 300 kW scale and at 1 MW scale, choosing the representative waste producing industries for such demonstration in different parts of the country. The demonstration may total up to 5 MWe with investment in research and development, testing and pilot technology development and manufacturing limited to INR 1 billion (12.50 million Euros). These initial demonstration projects must be 100% funded by the government through many of the mechanisms available from the Indian Ministry of Science & Technology, Indian Ministry of Power and Indian Ministry of Heavy Industry (MHI) using funding available from National Clean Energy Fund or National Innovation Fund Mechanism etc.

Technologies needed for this should be indigenously developed, and competent technology players may be enrolled to participate during the demonstration phase. Such demonstration phase should be completed in the shortest period of time, say about 2 years, and then one should move to the next phase where industry may invest 50% of the funds needed, and the rest of the 50% of the funds will come from the government.

The premise here is that from Phase 1 to the next phase sufficient experience would have been gained and would attract many other industries to adopt and participate in further development of these systems. The cost will still remain high since the economy of scale would not have kicked-in at this stage, and hence would require this support for some more time.

35

Phase 2 would, therefore, have to run for 5 years where sufficient number of systems would get built in the waste-heat landscape of the country. During this phase, the government contribution can be slowly reduced from 50% to a much lower value as the economy of scale would bring down the cost of the system as well. With this, the mechanism would become self-sustainable in due course of time, and will be able to proliferate itself without any external support. The Phase 2 may boost up from the 5 MW demonstration phase to 50 MW initial deployment phase. This will then set up the pace for full-fledged multiplication of the systems in the waste heat to power ecosystem.

For high temperature large quantity heat recovery, conventional steam turbine based system is already

or very near to economic viability. A small boost from policy and regulatory respects, would increase the conversion of waste heat to power by many folds. It is suggested that waste heat to power should be treated alike Renewable Energies, since the former is carbon neutral, and many a times not dependent on fossil fuels. In fact, this may also help reduce the issue of supplying more energy to the industries by reducing their energy consumption, as well as supply the electricity not only to the industry but also to the local community, thereby boosting the off-grid electricity supply market in the country.

Once the advance cycles, described above, completes the phase two program, small boosters mentioned above for the conventional cycles would make waste heat to power highly popular and also save precious

Waste Heat to Power

Large quantity hightemperature waste

Treatment atpar with

Renewable Power

Increasedorder of Meritfor Evacuation

100% fundingby GOI up to 5

Mwe demonstrationplant

Phase 1 Phase 2

Treatment at par with Renewable Power & Increased till the technology

gets fully developed

Late on

Industry & GOIcombined

investment up to50 Mwe plant

Low temperature waste heat

Conventionalsteam turbine

route

Advancetechnology

development

figure 19: Policy level intervention needed for making this waste to power a reality in india

36


foreign exchange for India from being spent on importing fossil fuels. For the Advance Cycles, the boost can be for a limited time as after a certain period (when technology gets fully developed), the price per unit of power generated will be same or fall below that of conventional steam based power generated from waste heat.

Figure 24 gives above recommendation pictorially.

Figure 25 gives an expected time lines and time till the boosts from the policy and the regulatory support are required.

The figure above shows the cost reduction trajectory for the new cycle in waste heat to power compared to the conventional cycles. Clearly the viability mark can be breached by the new cycles if the phase 1 and phase 2 strategy proposed above, is implemented properly in the country.

conclusions y Waste heat to power is the most flexible way to

recover energy from waste heat after the internal recovery of the heat is carried out within the process itself.

y Medium quality waste heat meaning process streams or waste streams with temperatures less than 300°C and with heat in quantity equivalent to 10 million kcal is the most challenging waste-heat to power solution. Current steam based cycle that is acceptable to waste heat above 450°C is not suitable for this range.

y The medium quality range should vary from 50 kW to 1 MW scale.

y Organic Rankine Cycle or Organic Hybrid Cycle are the most appropriate options in this range.

y Small boosts of considering waste heat to power at par with renewable energies and an increased merit order for power evacuation would make this concept very popular in the Indian Industry. For new cycles later on, this will not be required.

y Specific material used (i.e. kilogram of steel per kW) makes organic based systems, the ultimate cost effective solution, once sufficient numbers are needed in the industry.

y Innovative design of the waste heat exchanger including lower thickness and profile surfaces would make the balance of plant also less expensive.

y Organic cycle can be designed with waterless solutions and added on with attractive features.

figure 20: Expected time lines and time till boosts from policy and regulatory support required

16

14

12

10

8

6

4

2

0

No supportrequired

Pric

e Cr

/Mw

0 1 2 3 4 5 6 7 8 9 1 0

Number of yearsviability limit Conventional cycle New Cycles

37

y Demonstration scale plants are needed initially to identify suitable industrial sectors supported by the government funding for such projects. The total demonstration phase development may be limited to 5 MWe.

y Subsequent proliferation to 50 MW scale will go through partial funding. Over a period of time the funding will taper off till the industry system becomes self-sustainable. This is assumed to be over a period of five years.

y Such a development will bring in a virtuous cycle in every quarter of the society from the technology sector to the manufacturing sector. The savings in fossil fuels will be enormous once this development triggers low cost manufacturing in India.

casE stuDy

One of the first demonstration units for generation of power using ORC in distributed mode using Solar – Biomass hybrid concept is commissioned by Thermax India in December 2011 with the support from the Department of Science and Technology of

the Government of India in village Shive near Pune city in the state of Maharashtra. The plant, using the Organic Rankine Cycle technology, was implemented by Thermax India using the steam generated from the medium temperature parabolic trough solar collectors during sunny days in hybrid mode using biomass support during low radiation hours. The medium temperature solar collectors produce thermal energy in a cost effective manner and the same is converted to power in the most efficient way. The 125 KW ORC system is operating from 110 kW to as low as 30 kW capacity to meet varying demands of the village for agriculture pumps.

Also the plant has demonstrated that ORC can also run on varying heat supply that is common for renewable sources such as solar energy. Thermax India has experience of operating and maintaining the plant for over 2 years now in a rural environment. It has proved that ORC is the most suitable technology for solar power generation in hybrid and poly generation mode. In addition, Thermax India has installed another ORC unit at the Indian Institute of Sciences (IISc) campus at Bangalore in Karnataka, India for research and academic purposes.

Disclaimer: The assumptions, views and opinions expressed in this article are those of the authors and/or the organisation to which they belong to or are affiliated with. They do not reflect the official policy or position of neither the Indo-German Energy Forum (IGEF) – Support Office and the Bureau of Energy Efficiency (BEE) of the Indian Ministry of Power (MOP), nor that of any other author or contributor to this publication. Any person relying on any of the information contained in this publication or making any use of the information contained herein, shall do so at its own risk. The Indo-German Energy Forum (IGEF) – Support Office, the Bureau of Energy Efficiency (BEE) of the Indian Ministry of Power (MOP) and all other authors or contributors to this publication hereby disclaim any liability and shall not be held liable for any damages including, without limitation, direct, indirect or consequential damages including loss of revenue, loss of profit, loss of opportunity or other loss of any kind.

38


figure 21: in house test installation at thermax r&D center for experimentation and development purposes installed in 2010

figure 22: orc Plant manufactured by thermax for iisc Bangalore for research and academic purposes

Photo by Thermax India Ltd.

Photo by Thermax India Ltd.


gErman inDustry on orc: aPProach PaPEr anD casE stuDy By DÜrr

cyPlan ltD.

40


The Stadtwerke Groß-Gerau Versorgungs-GmbH (GGV) municipal utility company has invested in an energy-efficient Organic Rankine Cycle (ORC) system from Dürr Cyplan, and thereby increased the power to heat ratio of its cogeneration units (Combined Heat and Power or CHP). Since the end of 2007, the biogas system of this municipal utility company has been converting biomass to biogas in order to fire two CHP units. The Dürr ORC system, integrated in November 2012, increases the efficiency of electricity generation and improves the heat utilization concept.

So far, the two CHP units have produced 8.3 million kilowatt-hours of electricity per year, providing power to around 7,100 end-users. The heat produced in the process is used to heat the municipal utility company’s buildings and also those of the neighbouring companies. Additionally, the fermenter and post-fermenter are also heated. The temperatures are maintained at a constant level of 40 degrees Celsius (40°C) to ensure ideal living conditions for the microbes responsible for the fermentation and outgassing processes. During the summer, the heat is also used to dry herbs in a neighbouring agricultural operation. “The concept, thus, corresponds to the fundamental idea of combined heat and power (CHP), according to which the energy is simultaneously converted to electrical power and heat and used,” says GGV Managing Director Paul Weber.

DÜrr orc tEchnology

The integration of the ORC system from Dürr, the system construction specialist, enhances comprehensive the energy utilization. ORC stands for “Organic Rankine Cycle” – a procedure that uses waste heat to produce electricity with the aid of an evaporation process. In Groß-Gerau, the high-temperature flue gas waste heat from a CHP unit with an electrical output of 800 kWe is used for this purpose. “This proven principle produces 60 kWe of additional power on average,” explains Dürr project leader Timm Greschner. “No heat is lost in the process, no matter whether or not a concept for heat utilization exists. Up to 18% of the total heat in the flue gas is converted to electricity, and the remaining (approx. 82%) is provided at a temperature level of up to 90ºC.” A significant efficiency increase in power generation has, therefore, been realized in Groß-Gerau without restricting the existing heat utilization concept.

The ORC system is simple, robust and easily integrated into the overall system. Since there is no complex intermediate circuit and no separate turbine lubrication with lubricating oil, the system operation is also very stable. The ORC system uses the flue-gas heat throughout the year and also produces full power in the summer, thanks to the high condensation level.

Economic EfficiEncy

This investment has been worthwhile for the Stadtwerke Groß-Gerau municipal utility company. The integration of the ORC system permitted the exhaust-air heat exchanger behind the CHP unit to be omitted. The total electrical power generated is increased from 8.3 to more than 8.7 million kWh. This allows electricity to be provided to around 360 or more end-users. Despite the omission of the exhaust-air heat exchanger, the heat is fed into the heating network and is fully available for herb drying and for heating the administration building, the fermenter and the post-fermenter. The amortization period of such an ORC investment is five years with an electricity buyback price of 20.3 Euro cents/kWh and 7,500 hours of full utilization. With a depreciation period of ten years, this corresponds to an internal rate of return of 15.6%. The use of ORC technology perceptibly increases the CHP remuneration. According to the recommendation from the clearing office for the German Renewable Energy Law dated

figure 23: orc system in groß-gerau

Photo by Dürr Cyplan Ltd.

41

November 25th, 2010, “Systems with heat extraction (…) are to be considered as a unit for the purpose of determining the power to heat ratio if a device is used to convert the extracted heat into electricity by means of an additional generator.” Consequently, the power to heat ratio of the overall system consisting of a CHP unit and an ORC improves according to the formula below.

The CHP remuneration results from the sum of the externally used heat multiplied by the power to heat ratio and by the CHP bonus. This means that the remuneration automatically rises when the power to heat ratio is increased by the ORC system. With unchanging heat utilization, the CHP income increases by 17.6% with a retrofitted CHP unit. In the case of heat utilization with a dryer (e.g. a wood, digestate or herb dryer) of 1.5 million kWh/a, the resulting additional CHP income is around 7,100 Euros per year.

othEr aPPlications

“Beyond the use in CHP concepts, ORC systems from Dürr are suitable for a broad range of applications. The energy-efficient technology from Dürr generally can be coupled with the most diverse combustion

engines and waste-heat sources. Waste heat is one of the largest unused potential sources of energy in Germany,” explains Frank Eckert, Managing Director of Dürr Cyplan. “Waste heat from industry, firing systems, and the use of geothermal heat sources are especially attractive application options for ORC technology, which assists in developing energy-efficiency potentials as well as attractive returns on capital.”

aBout DÜrr

Dürr is a mechanical and plant engineering group that holds leading positions in the world market in its areas of operation. It generates more than 80% of its sales in business with the automotive industry. It furthermore supplies the aircraft, machinery, chemical, and pharmaceutical industries with innovative production and environmental technology. The Dürr Group operates in the market with four divisions: Paint and Assembly Systems plans and builds paint shops and final assembly plants for the automotive and aviation industries. Application Technology provides the automatic application of paint, sealants and adhesives with its robot technologies. Machinery and systems from the Measuring and Process Systems division are used in balancing and cleaning, in engine

figure 24: the flow chart schematically shows the system integration after the orc expansion

Biogas System

Biogas Flue gas

CHP

800

kWel

60 k

Wel

ORC

Heating network 900C

Dryer for herbsHeating of buildings

42


figure 25: improvement of the power to heat ratio of a similar chP unit with 834 kwe and 904 kwth

and transmission manufacturing and in final vehicle assembly, among other areas. The fourth division, Clean Technology Systems, is focused on processes to improve energy efficiency and on exhaust air purification. Dürr employs approx. 7,300 people at over 50 locations in 23 countries worldwide. In fiscal, 2011 Dürr achieved sales of around 1.9 billion Euros.

Disclaimer: The assumptions, views and opinions expressed in this article are those of the authors and/or the organisation to which they belong to or are affiliated with. They do not reflect the official policy or position of neither the Indo-German Energy Forum (IGEF) – Support Office and the Bureau of Energy Efficiency (BEE) of the Indian Ministry of Power (MOP), nor that of any other author or contributor to this publication. Any person relying on any of the information contained in this publication or making any use of the information contained herein, shall do so at its own risk. The Indo-German Energy Forum (IGEF) – Support Office, the Bureau of Energy Efficiency (BEE) of the Indian Ministry of Power (MOP) and all other authors or contributors to this publication hereby disclaim any liability and shall not be held liable for any damages including, without limitation, direct, indirect or consequential damages including loss of revenue, loss of profit, loss of opportunity or other loss of any kind.


challEngEs for wastE hEat rEcovEry ProjEcts

in inDia anD thE way forwarD

44


Even though there have been a number of projects in various Indian industries that employ the waste heat recovery methodology of the CDM, the potential of waste heat recovery is still not fully tapped. Some of the reasons for this potential not being tapped fully till now are:

1. The waste heat from cement plants has a lower temperature than the waste heat from many other industries, such as iron and steel. Since traditional steam power cycles need high waste heat temperatures, these technologies have not penetrated much in the sector. On the other hand this is an opportunity for the Organic Rankine Cycle technology that utilises such low temperature waste heat, but the full potential of the technology is yet to be demonstrated for mass adoption.

2. The waste gases from many industries contain large amounts of particulate material that need to be removed before feeding them to the boiler or heat recovery units. This leads to a higher cost of power generation, reducing the feasibility of the projects in many cases.

3. Non-availability of technology within the country is another major hurdle. The import of technology leads to high capital expenditure, something that many of the depressed industries may not find feasible.

4. The high capital cost makes it unattractive for companies to install these systems. A waste heat recovery unit for power generation based on ORC is INR 10 to 13 crores per MW, even more than per MW cost of any renewable technology, the latter being highly incentivised by the government through schemes such as the Feed In Tariffs (FIT), Generation Based Incentives (GBI), Accelerated Depriciation (AD) etc. It should be noted that these schemes are to a large extent responsible for bringing the cost of renewable energy at par with the energy from conventional sources. Similar schemes are there for energy efficiency initiatives, but are so few in number or the financial impact is so low that many a times in the end the cost of technologies, such as ORC, becomes prohibitive.

5. There is also a lack of demonstration projects of ORC technologies in Indian industrial sector to show its applicability for the low temperature waste heat sources. The few installations that are there in the country are for research or for academic purposes, and thus the financial

viabilities have never really been fully explored.

6. The flue gas generated from the furnace in the glass industry has significant amount of corrosive components, such as SOx and NOx, dust and traces of chlorides, fluorides and metals, present as impurities in the raw materials. This reduces the service life of the waste heat recovery system leading to higher operating and maintenance costs of such systems. More capacity building efforts must be taken up for the technicians

7. Since the waste heat recovery systems are directly coupled with the manufacturing processes, any operational failure in such system leads to system downtime, thereby, causing production losses. This also has caused many of the industries to shy away from installing such systems, a fear that can be removed if more manufacturers of these systems come in direct contact with the customers to show the systems have functioned in difficult conditions over years without any issues.

The potential of using ORC technology in India, assessed above, is thus approximately 4,406 MW out of which 758 MW can be installed in just three manufacturing industry segments (Cement, Iron & Steel and Glass). Although this gives an idea of the possible applications of this technology in India, although determining the realisable potential and acceptability in these industrial sectors requires more in-depth sector-wise analysis. Challenges faced by the industry related to financing, technology and regulatory issues needs to be identified and addressed by involving various stakeholders such as governments, technology providers, and financial institutions. Different business models (ESCO, RESCO, captive power plants, third party sale, sale to DISCOMs etc.) needs to be explored to bridge the gap in the viability of such projects.


annExurE

46


anne

xure

1: l

ist

of w

aste

hea

t re

cove

ry p

roje

cts

used

for

pow

er g

ener

atio

n re

gist

ered

und

er t

he c

lean

dev

elop

men

t m

echa

nism

in in

dia

s.

no.

capa

city

of

pow

er

gene

ratio

n

cDm

sta

tus

of th

e Pr

ojec

tco

mpa

nylo

catio

nin

dust

ry t

ype

type

of t

echn

olog

y us

ed

aver

age

annu

al

Emis

sion

re

duct

ion

(mt

co2

per

annu

m)

18

MW

Appr

oved

OCL

Indi

a Lt

dR

ajga

ngpu

r, Su

nder

garh

Dis

t. O

riss

a S

pong

e Ir

onR

anki

ne C

ycle

32,4

98

280

0 kW

Appr

oved

Guj

arat

Alk

alis

and

Ch

emic

als

Lim

ited

Dah

ej, G

ujar

atAl

kalis

and

Ch

emic

als

Ran

kine

Cyc

le4,

631

315

MW

Appr

oved

CCIL

Gha

ziab

ad, U

ttar

Pr

ades

hCa

rbon

bla

ck

Ran

kine

Cyc

le45

,725

425

.2 M

WAp

prov

edM

/s H

i-Te

ch C

arbo

n (A

dity

a B

irla

Nuv

o Lt

d)

Gum

mid

ipoo

ndi,T

amil

Nad

uCa

rbon

bla

ck

man

ufac

turi

ngR

anki

ne C

ycle

87,3

05

511

.30

MW

Appr

oved

Phill

ips

Carb

on

Bla

ck L

tdPa

lej,

Guj

arat

Carb

on b

lack

m

anuf

actu

ring

Ran

kine

Cyc

le45

,721

64

MW

Appr

oved

Ultr

atec

h Ce

men

tTa

dipa

tri,

Andh

ra

Prad

esh

Cem

ent

Org

anic

Ran

kine

Cyc

le16

,871

712

MW

Appr

oved

Lanc

o In

dust

ries

Li

mite

dCh

ittor

, And

hra

Prad

esh

Cem

ent

Ran

kine

Cyc

le78

,380

87.

7 M

WAp

prov

edIn

dia

Cem

ents

Vish

nupu

ram

, N

alag

onda

, And

hra

Prad

esh

Cem

ent

Ran

kine

Cyc

le51

,527

92.

35Ap

prov

edK

CP L

imite

d G

untu

r, An

dhra

Pr

ades

hCe

men

tR

anki

ne C

ycle

7,76

6

47

s.

no.

capa

city

of

pow

er

gene

ratio

n

cDm

sta

tus

of th

e Pr

ojec

tco

mpa

nylo

catio

nin

dust

ry t

ype

type

of t

echn

olog

y us

ed

aver

age

annu

al

Emis

sion

re

duct

ion

(mt

co2

per

annu

m)

1013

.2 M

WAp

prov

edJK

Cem

ent W

orks

Nim

bahe

ra,

Chitt

orga

rh,

Raj

asth

anCe

men

t R

anki

ne C

ycle

70,7

96

1111

.2 M

WAp

prov

edSt

erlit

e In

dust

ries

(In

dia)

Lim

ited

Tutic

orin

, Tam

il N

adu

copp

er, a

lum

iniu

m

and

zinc

Ran

kine

Cyc

le18

,082

1211

.2 M

WAp

prov

edSt

relit

e In

dust

ries

In

dia

Lim

ited

Tutic

orin

, Tam

il N

adu

copp

er, a

lum

iniu

m

and

zinc

Ran

kine

Cyc

le22

,473

131.

23 M

WAp

prov

edSa

int-

Gob

ain

Gla

ss

Indi

a ltd

(SG

GI)

Tam

il N

adu

Gla

ssR

anki

ne C

ycle

7,85

4

141.

5 M

WVa

lidat

ion

Asah

i Ind

ia G

lass

Li

mite

dTa

loja

, Mah

aras

htra

Gla

ssR

anki

ne C

ycle

10,4

08

1517

MW

Appr

oved

Sing

hal E

nter

pris

es

Pvt.

Ltd

Ger

wan

i, Ch

attis

garh

Iron

Ran

kine

Cyc

le1,

12,9

60

1617

.7 M

WAp

prov

edSr

ee M

etal

iks

Ltd.

Keo

njha

r, O

riss

aIr

onR

anki

ne C

ycle

1,01

,662

1725

MW

Appr

oved

God

awar

i Pow

er &

Is

pat L

tdR

aipu

r, Ch

attis

garh

Iron

Ran

kine

Cyc

le1,

59,9

26

184.

5 M

WAp

prov

edH

i-te

ch P

ower

&

Stee

l lim

ited

Rai

pur,

Chat

tisga

rhIr

onR

anki

ne C

ycle

31,2

09

1911

.5 M

WAp

prov

edG

opan

i Iro

n an

d Po

wer

(Ind

ia) P

vt.

Ltd.

Chan

drap

ur,

Mah

aras

htra

Iron

Ran

kine

Cyc

le54

,579

204

MW

Appr

oved

Mah

endr

a Sp

onge

&

Pow

er P

vt. L

td.

Silta

ra, C

hatt

isga

rhIr

onR

anki

ne C

ycle

19,1

51

48


s.

no.

capa

city

of

pow

er

gene

ratio

n

cDm

sta

tus

of th

e Pr

ojec

tco

mpa

nylo

catio

nin

dust

ry t

ype

type

of t

echn

olog

y us

ed

aver

age

annu

al

Emis

sion

re

duct

ion

(mt

co2

per

annu

m)

214

MW

Appr

oved

G.R

. Spo

nge

and

Pow

er L

tdR

aipu

r, Ch

attis

garh

Iron

Ran

kine

Cyc

le19

,150

2210

MW

Appr

oved

Kam

achi

Spo

nge

and

Pow

er C

orpo

ratio

n Li

mite

dTi

ruva

llur,

tam

il N

adu

Iron

Ran

kine

Cyc

le42

,910

2310

MW

Appr

oved

Vika

sh M

etal

&

Pow

er L

imite

dPu

ruliy

a, W

est B

enga

lIr

onR

anki

ne C

ycle

55,1

31

2430

MW

Appr

oved

Sesa

Goa

Lim

ited

&

Vide

ocon

Intl

Ltd

Bic

holim

, Goa

Iron

Ran

kine

Cyc

le1,

12,3

57

2516

MW

Appr

oved

Actio

n Is

pat &

Pow

er

(P) L

tdJh

arsu

guda

, Ori

ssa

Iron

R

anki

ne C

ycle

88,2

06

2610

MW

Appr

oved

God

awar

i Pow

er &

Is

pat L

tdR

aiga

rh, C

hhat

isga

rhIr

on &

Ste

elR

anki

ne C

ycle

50,6

20

2710

MW

Appr

oved

Ori

ssa

Spon

ge Ir

on

Lim

ited

Keo

njha

r, O

riss

aIr

on &

Ste

elR

anki

ne C

ycle

41,0

52

287

MW

Appr

oved

God

awar

i Pow

er a

nd

Ispa

t Ltd

(GPI

L)R

aipu

r, Ch

hatt

isga

rhIr

on &

Ste

elR

anki

ne C

ycle

17,8

28

2918

MW

Appr

oved

Shri

Baj

rang

Pow

er

& Is

pat L

imite

dR

aipu

r, Ch

hatt

isga

rhIr

on &

Ste

elR

anki

ne C

ycle

1,07

,683

306

MW

Appr

oved

Shre

e N

akod

a Is

pat

Ltd

Rai

pur,

Chha

ttis

garh

Iron

& S

teel

Ran

kine

Cyc

le32

,873

3116

MW

Appr

oved

Nal

wa

Spon

ge Ir

on

Lim

ited

Rai

garh

, Chh

atis

garh

Iron

& S

teel

Ran

kine

Cyc

le37

,825

3230

MW

Rej

ecte

dEl

ectr

othe

rm In

dia

Lim

ited

Kut

ch, G

ujar

atIr

on &

Ste

elR

anki

ne C

ycle

61,3

86

3310

.7 M

WR

ejec

ted

Adhu

nik

Met

alik

s Li

mite

dSu

ndar

garh

, Ori

ssa

Iron

& S

teel

Ran

kine

Cyc

le80

,065

49

s.

no.

capa

city

of

pow

er

gene

ratio

n

cDm

sta

tus

of th

e Pr

ojec

tco

mpa

nylo

catio

nin

dust

ry t

ype

type

of t

echn

olog

y us

ed

aver

age

annu

al

Emis

sion

re

duct

ion

(mt

co2

per

annu

m)

3445

MW

Rej

ecte

dB

hush

an P

ower

&

Stee

l Lim

ited

Sam

balp

ur, O

riss

aIr

on &

Ste

elR

anki

ne C

ycle

3,33

,481

3512

MW

Rej

ecte

dAn

kit M

etal

s &

Po

wer

Lim

ited

Ban

kura

, Wes

t Ben

gal

Iron

& S

teel

Ran

kine

Cyc

le26

,808

3615

MW

With

draw

nVi

sion

Spo

nge

Iron

Pv

t Ltd

Puru

liya,

Wes

t Ben

gal

Iron

& S

teel

Ran

kine

Cyc

le59

,320

3716

MW

Appr

oved

Ind

Syne

rgy

Lim

ited

Kot

mar

, Rai

garh

, Ch

attis

garh

Iron

and

Pow

erR

anki

ne C

ycle

30,2

22

384.

75 M

WAp

prov

edR

ashm

i Spo

nge

Indu

a Pv

t. Lt

dR

aiga

rh, C

hhat

isga

rhIr

on a

nd S

teel

Ran

kine

Cyc

le23

,887

3925

MW

Appr

oved

SKS

Ispa

t Lim

ited

Rai

pur,

Chat

tisga

rhIr

on a

nd S

teel

Ran

kine

Cyc

le1,

16,7

73

408

MW

Appr

oved

Kal

yani

Ste

els

Ltd

Gin

iger

a, K

oppa

l Dis

t. K

arna

taka

Iron

man

ufac

turi

ngR

anki

ne C

ycle

62,9

58

4112

.075

MW

Appr

oved

Num

alig

arh

Refi

nery

Li

mite

dG

olag

hat,

Assa

mO

ilR

anki

ne C

ycle

41,8

85

4215

MW

Appr

oved

SHYA

M D

RI P

ower

Lt

dSa

mba

lpur

, Ori

ssa

Pow

erR

anki

ne C

ycle

94,3

03

434.

5 M

WAp

prov

edM

/s A

arti

Spon

ge &

Po

wer

Ltd

Rai

pur,

Chat

tisga

rhPo

wer

Ran

kine

Cyc

le31

,209

50


s.

no.

capa

city

of

pow

er

gene

ratio

n

cDm

sta

tus

of th

e Pr

ojec

tco

mpa

nylo

catio

nin

dust

ry t

ype

type

of t

echn

olog

y us

ed

aver

age

annu

al

Emis

sion

re

duct

ion

(mt

co2

per

annu

m)

4426

0 M

WAp

prov

edJS

W E

nerg

yB

ella

ry, K

arna

taka

Pow

erR

anki

ne C

ycle

12,6

7,39

2

4510

0 M

WAp

prov

edJS

W P

ower

Lim

ited

Tora

ngal

lu in

K

arna

taka

, Ind

iaPo

wer

Ran

kine

Cyc

le7,

67,3

25

469

MW

Appr

oved

Jai B

alaj

i Spo

nge

Ltd

Ran

igun

j, W

est

Ben

gal

Spon

ge Ir

on

Man

ufac

turi

ngR

anki

ne C

ycle

46,3

87

474

MW

Appr

oved

Vand

ana

Glo

bal L

tdR

aipu

r, Ch

hatt

isga

rhSp

onge

Iron

M

anuf

actu

ring

Ran

kine

Cyc

le18

,965

487.

5 M

WAp

prov

edTa

ta S

pong

e Ir

on L

tdJo

da, O

riss

aSp

onge

iron

m

anuf

actu

ring

Ran

kine

Cyc

le31

,762

498.

1 M

WAp

prov

edM

/s T

ata

Stee

l Li

mite

dJa

msh

edpu

r, Jh

arkh

and

Stee

lTo

p Pr

essu

re R

ecov

ery

Turb

ine

60,8

11

5013

MW

Appr

oved

Jind

al S

tain

less

Li

mite

dD

ubur

i, O

riss

aSt

eel

Ran

kine

Cyc

le75

,187

518

MW

Appr

oved

VKG

Ste

el &

Ene

rgy

Pvt.

Ltd.

Kan

chee

pura

m, T

amil

Nad

uSt

eel

Ran

kine

Cyc

le36

,698

5220

MW

Appr

oved

Ram

saru

p Lo

hh

Udy

og L

imite

dK

hara

gpur

, Wes

t B

enga

lSt

eel

Ran

kine

Cyc

le1,

14,9

96

5315

MW

Appr

oved

Jind

al S

aw L

imite

dM

undr

a, G

ujar

atSt

eel

Ran

kine

Cyc

le70

,090

5416

MW

Appr

oved

MSP

Ste

el &

Pow

er

Lim

ited

Rai

garh

, Chh

atis

garh

Stee

lR

anki

ne C

ycle

59,0

97

5510

MW

Appr

oved

Ush

a M

artin

Lim

ited

Jam

shed

pur,

Jhar

khan

dSt

eel

Ran

kine

Cyc

le54

,340

51

s.

no.

capa

city

of

pow

er

gene

ratio

n

cDm

sta

tus

of th

e Pr

ojec

tco

mpa

nylo

catio

nin

dust

ry t

ype

type

of t

echn

olog

y us

ed

aver

age

annu

al

Emis

sion

re

duct

ion

(mt

co2

per

annu

m)

5612

MW

Appr

oved

Elec

tros

teel

Ca

stin

gs L

imite

dM

idna

pore

, Wes

t B

enga

lSt

eel

Ran

kine

Cyc

le52

,330

5775

MW

Appr

oved

Jind

al S

teel

& P

ower

Lt

d (J

SPL)

Vill

age

Patr

apal

i, R

aiga

rh, C

hhat

tisga

rhSt

eel

Ran

kine

Cyc

le3,

87,6

43

589.

6 M

WAp

prov

edSr

i Ram

rupa

i B

alaj

i Ste

el L

imite

d (S

RB

SL)

Bur

dwan

Dis

tric

t, W

est B

enga

lSt

eel

Ran

kine

Cyc

le51

,504

594.

5 M

WAp

prov

edSa

lasa

r St

eel a

nd

Pow

er L

imite

dR

aiga

rh, C

hhat

isga

rhSt

eel &

Pow

erR

anki

ne C

ycle

28,3

58

6011

MW

Appr

oved

AML

Stee

l and

Po

wer

Ltd

Sera

ikel

a, J

hark

hand

Stee

l & P

ower

Ran

kine

Cyc

le57

,872

6159

.5 M

WAp

prov

edM

onne

t Isp

at &

En

ergy

ltd

Kur

ud V

illag

e, R

aipu

r Ch

hatt

isga

rhSt

eel &

Pow

erR

anki

ne C

ycle

1,18

,383

625.

5 M

WAp

prov

edAp

ollo

Tyr

es L

imite

dVa

doda

ra, G

ujar

atTy

res

Ran

kine

Cyc

le23

,429

639.

4 M

WAp

prov

edH

indu

stan

Zin

c Li

mite

dCh

ande

ria,

Raj

asth

anZi

ncR

anki

ne C

ycle

51,6

09

about the indo-german Energy forum (igEf)

Background and ObjectivesTo enhance and deepen the cooperation between India and Germany in the energy sector, the German Chancellor Dr. Angela Merkel and the Indian Prime Minister Dr. Manmohan Singh established the Indo-German Energy Forum (IGEF) at the Hannover Fair in April 2006.

The main objectives of the IGEF are to rehabilitate and modernise thermal power plants to encourage the use of clean energy sources to disseminate climate-friendly technologies on the energy supply and demand side.

The dialogue focuses on exchanging knowledge, promoting private sector activities and putting in place an enabling environment to further develop the markets for efficient thermal power plant technologies, energy efficiency and renewable energies in India and Germany.

Partners, Institutional Structure and ProjectsThe high level steering committee of the IGEF, also called the “Forum”, takes place annually and provides a platform for high-level policy makers and representatives from industry, associations, financial institutions and research organizations from both India and Germany. On a working level, thematic sub groups have been created which convene meetings on a regular basis:

Efficiency Enhancement in Fossil Fuel Based Power Plants Renewable Energies Demand-Side Energy Efficiency and Low Carbon Growth Strategies.

Within the sub groups, several task forces have been set up to devise and implement specific cooperation projects, such as the harmonisation of tender documents for the rehabilitation and modernization of thermal power plant, the Excellence Enhancement Centre for the Indian power sector or the development of an energy performance assessment tool for residential buildings. Additional task forces concerning further topics may be created at the initiative of representatives of the relevant government agencies, private sector and other experts. The Indo-German Energy Symposium provides energy experts from India and Germany a platform for technical exchange and has given further momentum to the bilateral dialogue. The Symposium takes place on a biannual basis and covers aspects of financing, project development, best practices as well as innovative technologies and policy issues.

Ministry of New and Renewable EnergyGovernment Of India

Federal Ministryfor Economic Affairsand Energy

Federal Ministry for theEnvironment, Nature Conservation,Building and Nuclear Safety

Federal Ministryfor Economic Cooperationand Development

MARKET POTENTIAL STUDY FOR ORGANICRANKINE CYCLE TECHNOLOGY IN INDIAA Publication on Industrial Energy Efficiency

NEW DELHIIndo-German Energy Forum (IGEF)c/o Deutsche Gesellschaft fürInternationale Zusammenarbeit, (GIZ) GmbH,1st Floor, B-5/2, SafdarjungEnclaveNew Delhi – 110 029, India

T +91 11 4949 5353M [email protected] www.energyforum.in

CONTACTS

The IGEF Support Office can be reached at the following addresses:-

BERLINIndo-German Energy Forum (IGEF)c/o Deutsche Gesellschaft fürInternationale Zusammenarbeit, (GIZ) GmbH,Köthenerstraße 2, 10963 Berlin, Germany

T +49 30338424 462M [email protected] www.energyforum.in



CONTACTS MARKET POTENTIAL STUDY FOR ORGANIC · PDF fileMARKET POTENTIAL STUDY FOR ORGANIC...

Documents

Transcript of CONTACTS MARKET POTENTIAL STUDY FOR ORGANIC · PDF fileMARKET POTENTIAL STUDY FOR ORGANIC...