Applying process integration methods to target for electricity production from industrial waste heat using Organic Rankine Cycle (ORC) technology

This paper presents the results of an investigation of power production from low temperature excess process heat from a chemical cluster using Organic Rankine Cycle (ORC) technology. Process simulations and process integration methods including Pinch Technology and Total Site Analysis (TSA) are used to estimate the potential for electricity production from excess heat from the cluster. Results of a previous TSA study indicate that ca. 192 MWheat of waste heat are available at 84 °C to 55 °C, a suitable temperature range for ORC applications. Process streams especially suitable for ORC power production are identified. Simulation results indicate that 14 MWheat of waste heat are available from a PE-reactor, which can be used to generate ca. 1 MWel. Costs of electricity production calculated range from 70 to 147 €/MWh depending on the cost for ORC integration. Economic risk evaluation indicates that pay-back periods lower than 4.5 years should not be expected at the electricity price and RES-E support (a European support system for renewable electricity) levels considered in this study. CO2 emission reductions of up to 5900 tonnes/year were estimated for the analysed case