Optimization of Organic Rankine Cycles for Waste Heat Recovery From Aluminum Production Plants
This paper presents the optimization of organic Rankine cycles (ORCs) for recovering waste heat from a hypothetical aluminum production plant to be installed in Norway. The case study is particularly interesting because it features two hot streams at different temperatures (the pot exhaust gases and...
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doaj-aec73fe7cb0049e6aefd1c9d90a29c502020-11-25T01:08:08ZengFrontiers Media S.A.Frontiers in Energy Research2296-598X2019-06-01710.3389/fenrg.2019.00044449220Optimization of Organic Rankine Cycles for Waste Heat Recovery From Aluminum Production PlantsAlessandro Francesco Castelli0Alessandro Francesco Castelli1Cristina Elsido2Roberto Scaccabarozzi3Lars O. Nord4Emanuele Martelli5Department of Energy, Politecnico di Milano, Milan, ItalyDepartment of Energy and Process Engineering, The Norwegian University of Science and Technology (NTNU), Trondheim, NorwayDepartment of Energy, Politecnico di Milano, Milan, ItalyDepartment of Energy, Politecnico di Milano, Milan, ItalyDepartment of Energy and Process Engineering, The Norwegian University of Science and Technology (NTNU), Trondheim, NorwayDepartment of Energy, Politecnico di Milano, Milan, ItalyThis paper presents the optimization of organic Rankine cycles (ORCs) for recovering waste heat from a hypothetical aluminum production plant to be installed in Norway. The case study is particularly interesting because it features two hot streams at different temperatures (the pot exhaust gases and the cell wall cooling air), which make available about 16 MWth below 250°C. First, a recently proposed cycle optimization approach is adopted to identify the most promising working fluid and optimize the cycle variables (pressures, temperatures, mass flow rates) for the maximum energy performance. The analysis includes both pure fluids, including recently synthesized refrigerants, and binary zeotropic mixtures assessing in total 102 working fluids. The best pure fluid in terms of exergy efficiency turns out to be HFE-347mcc (which can achieve a target exergy efficiency of 85.28%), followed by neopentane, butane, and R114. HFO-1336mzz appears to be one of the most promising non-flammable alternatives with low Global Warming Potential (GWP). The mixture leading to the highest exergy efficiency is isobutane–isopentane, which can increase the net electrical power output by up to 3.3% compared to pure fluids. The systematic techno-economic optimization, repeated for two different electricity prices, shows that RE347mcc is the best option in both low and high electricity prices. The cost of the cycle using HFO-1336mzz is penalized by the larger evaporation heat (negatively influencing the heat integration) and the smaller regenerator.https://www.frontiersin.org/article/10.3389/fenrg.2019.00044/fullorganic rankine cycle (ORC)waste heat recoveryoptimizationheat integrationzeotropic mixtureworking fluid |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Alessandro Francesco Castelli Alessandro Francesco Castelli Cristina Elsido Roberto Scaccabarozzi Lars O. Nord Emanuele Martelli |
spellingShingle |
Alessandro Francesco Castelli Alessandro Francesco Castelli Cristina Elsido Roberto Scaccabarozzi Lars O. Nord Emanuele Martelli Optimization of Organic Rankine Cycles for Waste Heat Recovery From Aluminum Production Plants Frontiers in Energy Research organic rankine cycle (ORC) waste heat recovery optimization heat integration zeotropic mixture working fluid |
author_facet |
Alessandro Francesco Castelli Alessandro Francesco Castelli Cristina Elsido Roberto Scaccabarozzi Lars O. Nord Emanuele Martelli |
author_sort |
Alessandro Francesco Castelli |
title |
Optimization of Organic Rankine Cycles for Waste Heat Recovery From Aluminum Production Plants |
title_short |
Optimization of Organic Rankine Cycles for Waste Heat Recovery From Aluminum Production Plants |
title_full |
Optimization of Organic Rankine Cycles for Waste Heat Recovery From Aluminum Production Plants |
title_fullStr |
Optimization of Organic Rankine Cycles for Waste Heat Recovery From Aluminum Production Plants |
title_full_unstemmed |
Optimization of Organic Rankine Cycles for Waste Heat Recovery From Aluminum Production Plants |
title_sort |
optimization of organic rankine cycles for waste heat recovery from aluminum production plants |
publisher |
Frontiers Media S.A. |
series |
Frontiers in Energy Research |
issn |
2296-598X |
publishDate |
2019-06-01 |
description |
This paper presents the optimization of organic Rankine cycles (ORCs) for recovering waste heat from a hypothetical aluminum production plant to be installed in Norway. The case study is particularly interesting because it features two hot streams at different temperatures (the pot exhaust gases and the cell wall cooling air), which make available about 16 MWth below 250°C. First, a recently proposed cycle optimization approach is adopted to identify the most promising working fluid and optimize the cycle variables (pressures, temperatures, mass flow rates) for the maximum energy performance. The analysis includes both pure fluids, including recently synthesized refrigerants, and binary zeotropic mixtures assessing in total 102 working fluids. The best pure fluid in terms of exergy efficiency turns out to be HFE-347mcc (which can achieve a target exergy efficiency of 85.28%), followed by neopentane, butane, and R114. HFO-1336mzz appears to be one of the most promising non-flammable alternatives with low Global Warming Potential (GWP). The mixture leading to the highest exergy efficiency is isobutane–isopentane, which can increase the net electrical power output by up to 3.3% compared to pure fluids. The systematic techno-economic optimization, repeated for two different electricity prices, shows that RE347mcc is the best option in both low and high electricity prices. The cost of the cycle using HFO-1336mzz is penalized by the larger evaporation heat (negatively influencing the heat integration) and the smaller regenerator. |
topic |
organic rankine cycle (ORC) waste heat recovery optimization heat integration zeotropic mixture working fluid |
url |
https://www.frontiersin.org/article/10.3389/fenrg.2019.00044/full |
work_keys_str_mv |
AT alessandrofrancescocastelli optimizationoforganicrankinecyclesforwasteheatrecoveryfromaluminumproductionplants AT alessandrofrancescocastelli optimizationoforganicrankinecyclesforwasteheatrecoveryfromaluminumproductionplants AT cristinaelsido optimizationoforganicrankinecyclesforwasteheatrecoveryfromaluminumproductionplants AT robertoscaccabarozzi optimizationoforganicrankinecyclesforwasteheatrecoveryfromaluminumproductionplants AT larsonord optimizationoforganicrankinecyclesforwasteheatrecoveryfromaluminumproductionplants AT emanuelemartelli optimizationoforganicrankinecyclesforwasteheatrecoveryfromaluminumproductionplants |
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