Energy-intensive processes process industry generate high amounts of waste emissions that are often unexploited. However, using their thermal energy would make good sense, both economically and ecologically, with regard to steadily rising energy costs, the need of companies to stay competitive, and increasingly strict environmental regulations. GEA offers gas cleaning and energy recovery systems that employ ORC technology (Organic Rankine System), proven to be the most efficient solution for this.
Discover the benefits of GEA ORC-Module
ORC energy recovery systems from GEA produce economical electricity for use in the further production process. Moreover, this solution contributes to the reduction of the entire CO2 footprint, since it generates no additional CO2 emissions.
Our experts will gladly calculate the economical and ecological efficiency of your project beforehand, so you will know in advance in which period it will reach ROI, depending on the specific system configuration and local circumstances.
The GEA energy recovery system
1 THE WASTE HEAT RECOVERY UNIT (WHRU)
The WHRU absorbs the gas from production or gas cleaning processes. In this unit, a number of tube banks are installed, depending on the required cooling temperature. Through the tubes flows a carrier fluid (thermal oil with a boiling point of max. 350 °C) which absorbs the heat from the gas with high efficiency. This setup allows for a flexible configuration of the ORC module.
2 THE ORC MODULE
In the ORC module, the carrier fluid from the WHRU initially passes a further
heat exchange step with an organic fluid (silicon oil). That fluid then evaporates in the super heater and evaporator, driving a turbine with a coupled generator to produce electricity. The cooled-down thermo oil returns to the WHRU. Emergency coolers and three-way valves regulate the oil temperature and ensure constant feeding of steam to the turbine.
3 THE AIR COOLERS
The remaining steam from the turbine in the ORC module is condensed by means of air coolers. The water thus produced returns to the heat exchange cycle in the ORC module.
OPTIONAL CLEANING SYSTEM
If the WHRU is to operate with crude gas from production processes, feeding of lime hydrate can prevent the formation of sodium pyrosulfate (Na2S2O7) and sodium bisulfate (NaHSO4) at the tube banks. A ball cleaning system has proved a good addition to stop substances from baking at the tube banks, using metal balls in a closed system.
Depending on the specific conditions in your production process, we can offer several planning options.
USE WITH CRUDE GAS
Highest temperature in the entire process, thus high efficiency.
USE WITH CLEAN GAS
Further use of the high temperature level possible. No cleaning system required.
BOTH METHODS IN COMBINATION
The higher investment pays off because of the high overall efficiency in the shortest time.
A sensible investment in energetic exploitation of waste heat will pay off in any situation:
In the last years the high prices of energy and the need to reduce CO2 emissions increased the importance of energy recovery applications for all industrial processes. Hot process gas going to the plant stack means losing valuable thermal energy which could be easily recovered and/or converted in electric power. Waste heat in industry is a potential resource that is often unexploited.
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