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. 2022 Dec 6;7(50):46099-46117.
doi: 10.1021/acsomega.2c03922. eCollection 2022 Dec 20.

Analysis of Different Organic Rankine and Kalina Cycles for Waste Heat Recovery in the Iron and Steel Industry

Davood Atashbozorg  1 , Afshin Mohseni Arasteh  2 , Gholamreza Salehi  3 , Masoud Torabi Azad  2
Affiliations

Analysis of Different Organic Rankine and Kalina Cycles for Waste Heat Recovery in the Iron and Steel Industry

Davood Atashbozorg et al. ACS Omega. .

Abstract

This study analyzed waste heat of two sections including the rolling section and electric arc furnace with low and medium temperature ranges, respectively. Organic Rankine cycles (ORCs) and Kalina cycles are the best technologies for the conversion of low-quality and medium-quality thermal energy to electrical power. The ORC applies the principle of the steam Rankine cycle, but it uses organic working fluids with low boiling points to recover heat from lower temperature heat sources. Also, in the Kalina cycle, ammonia water is selected as the working fluid because of its variable boiling point and thermodynamic properties. This study employs the thermo-economic method using the genetic algorithm to optimize the performance of three different ORC systems including a basic ORC (BORC) system, a single-stage regenerative ORC (SRORC) system, and a double-stage regenerative ORC (DRORC) system using five different working fluids and a basic Kalina cycle with KCS34 and complex cycle under the same waste heat conditions. Based on the energy and exergy analysis, the complex Kalina cycle shows the best performance among all studied cycles. The next best performance was exhibited by KCS34 and DROC, respectively. In general, Kalina cycles and ORCs are suitable for low-temperature and medium-temperature heat sources, respectively. According to the thermo-economic analysis, KCS34 in the rolling section and DRORC in EAF show optimum performance for heat recovery. R11 and R113 are selected as the best working fluids for ORCs, and ammonia with a concentration of 0.9 in the mixture is the optimal solution for Kalina cycles.

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Conflict of interest statement

The authors declare no competing financial interest.

Figures

Figure 1
Figure 1
Waste heat from a steel plant.
Figure 2
Figure 2
Basic organic Rankine cycle (BORC).
Figure 3
Figure 3
Single regenerative organic Rankine cycle (SRORC).
Figure 4
Figure 4
Double regenerative organic Rankine cycle (DRORC).
Figure 5
Figure 5
Basic Kalina cycle.
Figure 6
Figure 6
Kalina cycle system 34 (KCS34).
Figure 7
Figure 7
Complex Kalina cycle with preheaters.
Figure 8
Figure 8
Mass flow rate and net power for cycles in optimal conditions with various fluids.
Figure 9
Figure 9
Maximum energy and exergy efficiency for cycles in optimum conditions with various fluids.
Figure 10
Figure 10
Energy efficiency for ORCs in the optimum condition with turbine inlet pressure.
Figure 11
Figure 11
Energy efficiency for BORC, SRORC, and DRORC in optimum conditions with evaporator temperature.
Figure 12
Figure 12
Energy efficiency for SRORC, DRORC, and DRORC in the optimum condition with the extracted flow.
Figure 13
Figure 13
Energy efficiency for the basic, KCS34, and complex Kalina cycles in optimum conditions with turbine inlet pressure.
Figure 14
Figure 14
Energy efficiency for the Kalina cycles in optimum conditions with the concentration of ammonia.
Figure 15
Figure 15
Exergy efficiency for the basic, KCS34, and complex Kalina cycles in optimum conditions with the concentration of ammonia.
Figure 16
Figure 16
Mass flow rate of the working fluid for the basic, KCS34, and complex Kalina cycles in optimum conditions with the concentration of ammonia.
Figure 17
Figure 17
Exergy efficiency of ORCs in optimum conditions with evaporation pressure.
Figure 18
Figure 18
Specific power cost for ORCs in optimum conditions with evaporation pressure.
Figure 19
Figure 19
Exergy efficiency for ORCs in optimum conditions with superheat temperature.
Figure 20
Figure 20
Specific power cost for ORCs in optimum conditions with superheat temperature.
Figure 21
Figure 21
Exergy efficiency for the Kalina cycles in optimum conditions with evaporation pressure.
Figure 22
Figure 22
Specific power cost for the Kalina cycles in optimum conditions with evaporation pressure.
Figure 23
Figure 23
Exergy efficiency for the Kalina cycles in optimum conditions with superheat temperature.
Figure 24
Figure 24
Specific power cost for the Kalina cycles in the optimum conditions with superheat temperature.
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