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MARKET POTENTIAL STUDY FOR ORGANIC

RANKINE CYCLE TECHNOLOGY IN INDIA


A Publication on Industrial Energy Efficiency

BUREAU OF ENERGY EFFICIENCY


MARKET POTENTIAL STUDY FOR ORGANIC
RANKINE CYCLE TECHNOLOGY IN INDIA
Publication on Industrial Energy Efficiency

BUREAU OF ENERGY EFFICIENCY

CONSULTING PARTNER:- TECHNICAL PARTNERS:-


PUBLISHER:-

Indo-German Energy Forum Support Office (IGEF-SO),


c/o Deutsche Gesellschaft fr Internationale Zusammenarbeit (GIZ) GmbH,
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TECHNICAL PARTNERS:-

THERMAX INDIA Pvt. Ltd. DURR CYPLAN Ltd.


D-13, MIDC Industrial Area, Carl Benz Str-34, 74321
RDAGA Road, Chinchwada, Bietighetm Bissingen,
Pune - 410019, INDIA Germany

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+91 20 2747 5941 F : +49 7142 78-55 2469
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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)
BUREAU OF ENERGY EFFICIENCY

Executive
summary
Energy is a critical input in any industrial process, in India as solar or wind energy. In the solar thermal
and thus directly determines to a large extent, installations, as a technology that is gaining a solid
the environmental impact of the manufacturing foot in the Indian energy scenario, ORC can be used
process and the products of a any company. Most of to exploit the medium to low temperature steam to
the production processes involve heat energy that generate electricity. Bagasse based cogeneration
is generally produced by burning fossil fuels, as systems that are quite common in India, also have a
prime source of energy. Such production processes promising future for ORC installations in India.
are inherently energy inefficient, thereby losing a
significant amount of heat to equipment inefficiencies. In India, there are many industries, as mentioned
This study focuses on waste heat recovery, especially below, where the low temperature heat is expelled
the application of Organic Rankine Cycle (ORC) in the atmosphere without putting it to any practical
technology in the industrial sector in India. use. On the other hand, the ORC technology has been
commercially utilized in these sectors, especially in
ORC is a technology that operates similarly as the the developed world, to extract this waste heat.
Steam Rankine cycle, except that the former uses an
yy Industrial waste heat recovery applications (Iron
organic working fluid instead of steam. This organic
and Steel, Cement and Glass)
working fluid has a lower boiling point and a higher
vapour pressure than water, and is, thus able to use yy Internal combustion engines (ICE) and gas
low temperature heat sources to run a turbine for turbines
power generation. yy Renewable energy power plants (solar thermal,
biomass and geothermal)
ORC technology, although new to India, finds some yy Heat recovery from high temperature heater
very successful installations in the country. There are exhaust used in process such as textile, edible oil
a few installations in India based on this technology, refineries, etc.
notably a 4 MW waste heat recovery plant by
UltraTech Cements in Andhra Pradesh, India1 and the The total potential of electricity generation from
125 KW system installed in Pune by Thermax India ORC technology in India, including all the sectors,
Ltd. and the Department of Science and Technology has been assessed during this study to be roughly
of the Government of India. The latter installation around 4.4 GW by 2017. This potential is around
uses the steam generated from solar parabolic 574 MW in the Iron and Steel industry, 35 MW in the
troughs during the sunny days, in hybrid mode with Glass industry, 148 MW in the Cement industry, 1.4
biomass boiler during low radiation hours. There GW in the solar thermal industry and 2.4 GW in the
are two more installations by Thermax Limited, only Biomass industry all till 2017. The potential of using
for experimentation and research purposes - one in this technology is not considered in the internal
house installation since 2010 and the other supplied combustion engines and the gas turbines, both of
to IISc, Bangalore to be commissioned at their new which are used for captive power generation as there
campus. is no reliable aggregate data for such installations
in India, and thus, a detailed sector wise industry
The reasons for such low penetration of this analysis is required to explore further it. Unless the
technology in India are the low overall conversion total potential of geothermal energy is assessed, the
efficiency of the system to convert the heat from potential for ORC applications in this sector cannot
external source to electricity (owing to low waste heat be determined. Also the Indian biomass sector that
source temperatures), the high system cost, the lack although has still to go a long way, holds a promising
of indigenous manufacturing capability and the lack of future for stationary ORC applications, but currently
proper incentives. In addition, most opportunities for the absence of detailed data on this sector, makes
the deployment of the technology exists currently for such an assessment impossible. It must be noted, as
waste to heat recovery than for stationary applications mentioned earlier, that this biomass sector excludes
that use biomass or geothermal energy directly. This the bagasse based electricity generation and the
is because both biomass (except bagasse based cogeneration units. It is needless to mention here that
systems) and geothermal energy are not as popular if a quarter of this total potential is realised, then the
capital cost and the climate impact of building several
1
The Waste heat recovery project installed at Saint Gobain glass new thermal power units can be avoided apart from
manufacturing facility in Tamil Nadu uses the Steam Rankine cycle
technology.

i
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

mitigating the fear instilled by the ever increasing financial incentives are also available in India, such
fossil fuel prices. as the NMEEE, SECF, NCEF etc., but further analysis
is needed to find out how they would be applied for
From a broad industry analysis, it can thus be energy efficiency measures involving ORC systems.
concluded that the potential for ORC technology is Proper institutional set-up in India to promote such
significant in the industrial and renewable energy energy efficiency initiatives (such as the BEE) and the
sectors in India, but a detailed sector-wise analysis recent focus on off-grid power generation, can also
is needed in order to determine the exact potential of help proliferate the deployment of this technology
this technology accurately. that not only contributes to the energy security of the
country, but also helps mitigate the climate impact by
There are some technology providers in India for reducing the carbon emissions, apart from mitigating
ORC technology that include both Indian as well the need for new investments to build captive power
as the multi-national companies, however the plants that may be fossil fuel based.
majority of the foreign companies who specialise in
this technology, are yet to begin their work in India. Please note that the images in this document are
Different business models, such as the ESCO, RESCO, from those industries in which the ORC technology
captive power plants, third party sale of power, sale can be widely implemented, and are, thus, chosen
of power to the DISCOMs etc., are making the mass accordingly to give the reader an idea about the
scale adoption of many such new technologies easy several opportunities to save waste heat for
and commercially viable. In addition, policy and conversion to electrivity rather than being wasted.

ii
Wheelabrator Shasta Energy Company, Anderson, California (Photo by Warren Gretz / NREL , NREL No. 00071)
BUREAU OF ENERGY EFFICIENCY

contents
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 DRR 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

v
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

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

vi
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: O
 RC 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 Gro-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

vii
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

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

viii
BUREAU OF ENERGY EFFICIENCY

Power generation
through waste heat
recovery
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Heat losses arise both from equipment inefficiencies Figure 1: Schematic of Steam Rankine
and from thermodynamic limitations of equipment Cycle
and processes2. Heat is generated by fuel combustion
or by chemical reaction in a process in which part Electricity
of the heat generated is used up, and the rest of the Generator
Turbine
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,
Waste Condenser
much of the heat could be recovered and be used for heat from
various useful and economic purposes. This would Process Exhaust
Evaporator
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. Pump

Waste heat can be utilized in two forms utilising


the waste heat in thermal applications or converting The traditional Steam Rankine Cycle (SRC) has been
the waste heat in to electrical energy. Since the one the most efficient options for waste heat recovery
conversion of waste heat in to electricity involves from exhaust streams with temperatures above 650-
efficiency losses at each stage, it is preferred to 700F [340-370C]. At lower waste heat temperatures,
use the waste heat directly in thermal applications this cycle becomes less cost effective because of the
wherever possible, since the latter have comparatively following reasons:
lesser heat losses. In cases where this option is not
viable, the waste heat is converted in to electricity. yy Low pressure steam generated from low
This electricity generated is either consumed within temperature waste heat requires larger, bulkier
the process or is transferred to the grid. and costlier equipment.
yy Low temperature waste heat does not provide
Generation of power from waste heat typically sufficient energy to superheat the steam, which
involves the conversion of the (otherwise) waste heat causes steam to condense resulting in the erosion
to mechanical energy to drive an electric generator. of the turbine blades and other metallic units.
Industries have different processes which in some
way or the other involve dumping of heat into the For such low temperature waste heat recovery
atmosphere in the form of flue gases, hot water, applications, a better technology that may be used
steam etc. Heat can be recovered from these streams is the Organic Rankine Cycle since this cycle uses
and utilized through different thermodynamic cycles organic fluids that not only have lower boiling point
to generate power. The most frequently used system temperatures than steam has, but also do not corrode
for power generation from waste heat involves using the metallic parts of the equipment.
the heat to generate steam to drive a steam turbine, a
The Organic Rankine Cycle (ORC) is similar in
process commonly referred to as the Rankine Cycle, a
operation to the steam Rankine cycle, except the fact
schematic diagram of which is shown below in Figure
that the former uses an organic working fluid while
1.
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 150F [66C] a general characteristic of many
waste heat streams.
2
U.S. DOE Energy Efficiency and Renewable Energy, Waste Heat Recovery:
Technology and Opportunities in U.S. Industry http://www1.eere.energy.gov/ In comparison to water/steam that are used in the
manufacturing/intensiveprocesses/pdfs/waste_heat_recovery.pdf
3
Express India, MEDA Plans to Popularise Waste Heat Recovery Schemes SRCs, the organic fluids used in ORCs have higher
in Industries, January 2008 http://www.expressindia.com/latest-news/meda- molecular masses enabling compact designs, higher
plans-to-popularise-waste-heat-recovery-schemes-in-industries/263715/

2
mass flow rates, and higher turbine efficiencies (as Advantages and disadvantages
high as 80-85%). However, since the cycle functions
at lower temperatures, the overall efficiency is only of ORC technologies5,6
around 10-20%, depending on the temperature of the
condenser and evaporator. This overall efficiency of Advantages
conversion of heat into electricity of ORCs (10%-20%)
yy Large inlet temperatures ranging from 100C or
is lower than that of steam cycle (30%-40%) because
lower to as high as 450C;
the SRC operates at higher temperatures than the
ORC. This lower efficiency is due to the limitation yy ORC modules are easy to install (compact, skid-
based on thermodynamic principle called the Carnot mounted standard module) and very easy to
Theorem4. operate;
yy ORC systems require low maintenance (no droplet
Waste heat recovery through ORC systems can be erosion in the turbine, low pressure evaporator,
applied to a variety of low to medium temperature automation), thereby reducing the running costs

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


Potential waste heat ORC Process Power feed to grid
sources

Hot water cycle


120-150 oc
Industry

Heat exchanger Generator


(vaporiser)
Bioenergy Feed pump Turbine G
ORC cycle

Heat excharger
(condenser)
Solor energy

heat streams. An example of a recent successful greatly, and need very little maintenance downtime
installation in India is by UltraTech Cements India (< 2% of the operational time per annum);
Ltd. in Andhra Pradesh, India, where the installed yy System sizes range from a few kWe (down to
ORC plant recovers waste heat from the clinker 30kWe) to several MWe that make them perfectly
cooler that has an exhaust gas temperature of about suitable for tapping various thermal sources;
6080F [3200C]. The ORC installation can generate 4
yy For power capacities lower than 2 MWe, steam
MW of power, thereby reducing CO2 emissions by
power plants are usually not well adapted since
approximately 16,871 tons per annum.
the operation and maintenance costs of the
equivalent Steam Rankine Cycle are higher and
the system efficiency is lower;
yy Long working life of the system (20 years +) with
very minimum maintenance needs. Most of the
systems have very little or no turbine mechanical
4
Carnot theorem: No engine operating between two heat reservoirs
can be more efficient than a Carnot engine operating between those stress, while the closed leak proof systems
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 5
Enertime, World Engineers Convention, Waste Heat Recovery Projects
engine operating with a heat source at 300F [150C or 423K] and rejecting it Using organic Rankine Cycle Technology, September 2011 http://www.
at 77F [25C or 298K] is only about 30% efficient. In this light, an efficiency enertime.com/sites/www.enertime.com/files/documentation/whr_projects_
of 10-20% is a substantial percentage of theoretical efficiency, especially using_orc_publication-for-world-engineers-convention.pdf
in comparison to other low temperature options, such as piezoelectric 6
Ormat Energy Converters, Proven Power From Cement Plant Waste Heat
generation, which are only 1% efficient. http://www.ormat.com/research/papers/test

3
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

prevent moisture from reaching the metallic capacity are unlikely to use ORC technology for
turbine blades, thereby reducing the erosion levels power generation, unless the alternative cost of
to almost nil; power from the normal power supply is extremely
yy The systems have very simple start up procedures high.
coupled with automatic and continuous operation, yy This technology is relatively new in India and there
which rules out the requirement of continuous is only one manufacturer in the country. Import
operator attention; duties and custom duties may make this imported
yy Simple treatment of water is enough for supply technology too expensive to be used in many of the
to the system, for which no expense is there on industries, unless subsidies and tax holidays are
special water treatment; provided to incentivise energy efficiency achieved.
yy Since the organic compounds used have much yy Since the technology is not yet in the mainstream
higher molecular mass than water, the turbine unlike in Germany or other developed countries,
blades rotate slowly resulting in a much lower there is also a need for large scale capacity building
vapour pressure of the system, which in turn of the operators and maintenance technicians of
results in much higher system stability. the systems. Currently, the manufacturer of the
equipment, if based out of India, would really find
Disadvantages it difficult to provide after sales service if it imports
and sells the systems in the country, which then
yy The biggest weakness of the technology is the would become a reason for many people to shy
apparent low conversion efficiency of thermal away from installing the systems for a fear of
energy into electricity (between 10% and 25%). system breakdown.
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.
yy 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.
yy 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 Geothermal power plant close to El Centro, California
having capacities lower than 3000 tons per day (Photo by Warren Gretz / NREL , NREL No. 00442)

4
BUREAU OF ENERGY EFFICIENCY

organic rankine
cycle - technical
details
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Development of the Organic The concerns over the climate change impacts of
electricity generation from fossil fuels, coupled with
Rankine Cycle the rising prices of the latter, are fuelling the explosive
growth of the installations of the ORC systems all
Rankine Cycle is the process by which more than 80 over the world. In India, the huge focus on demand
percent of the worlds electricity is generated today. It side energy efficiency to increase energy security
is a thermodynamic cycle to convert heat energy into and to mitigate the need for addition of electricity
electricity, named after the Scottish engineer William generation capacity through various regulations (such
John Macquorn Rankine who is regarded as one of as the Energy Conservation Act 2001 and the NMEEE),
the fathers of thermodynamic science for developing institutions (such as the BEE), fiscal incentives (such
the theory of steam engine. as SECF and NCEF) and market mechanisms (such
as the PAT scheme) would help fuel the market for
The Rankine Cycle system that uses water as a
the ORC systems in the future. In addition, the use of
working fluid to take up external heat to run a steam
hydrocarbons over the hydrofluorocarbons (HFCs) in
turbine to generate electricity, is commonly referred
the ORC systems have resulted in further lowering
to as the Steam Rankine Cycle or the SRC. The SRCs
the carbon footprint of the systems.
have been used for nearly a century or more now to
generate electricity and would continue to be the It must also be noted that in India, the rapid growth
main stream in the near foreseeable future. However, of the renewable energies has also resulted in the
in 1883, when Frank Ofeldt developed an engine development of a biomass (bagasse based) and a
that boiled naphtha, rather than steam, to drive the solar thermal industry in the country, while its just a
pistons, it triggered the research into other organic matter of a little time before biomass (other forms)
fluids as the working fluid for power engines. and geothermal energies also develop hugely. Also
the fact that the ORC based systems can be used with
Later in the twentieth century, the Organic Rankine
biomass cogeneration systems, makes ORC a very
Cycle was developed using a variety of organic fluids
suitable technology for India, where there are many
such as the Hydrocarbons and the Hydrofluorocarbons
bagasse based cogeneration units. ORC systems find
or HFCs. The ORC systems are today mostly designed
application in all of these renewable based industries,
to extract heat from various renewable sources, such
and thus, both the Indian and the German companies
as the biomass and the geothermal sources, and for
are already making efforts to commercialise the
the recovery of low to medium temperature waste
technology in the country. The case studies mentioned
heat from a variety of industrial processes. However,
in the subsequent chapters help in strengthening this
with the solar thermal systems becoming more
point.
and more popular, the ORC systems find successful
applications there as well.

The use of SRCs to recover high temperature waste


System Components
heat for conversion into electricity is quite widespread,
but the low temperature waste heat could not be The major components of an ORC system are the
recovered for long, except for minor uses such as following:-
minimal preheating. However, the way that ORC yy Heat exchangers (preheater, evaporator, cooling
systems have evolved today, these low temperature and condensing units)
waste heat sources are now getting prominence to yy A regenerator (used mostly in waste heat recovery
add to the overall energy efficiency o f t he i ndustrial systems)
processes. In addition, power cuts that haunt many
yy An expander (mostly positive displacement
industries in India, would no longer pose much of
systems such as scroll and screw expanders
a threat if such low temperature waste heat can be
rather than turbo machines)
recovered to produce electricity since it reduces
dependency on the electrical grids. In addition to yy A turbine
this, it may help the usage of heat generated from yy A generator
low irradiation on solar thermal plants or from low yy Ancillary systems include pumps, instrumentation
calorific value biomass. and control systems, online control panel and an
electricity feeder (to be connected to the electrical
transmission system).

6
yy System monitoring is done mostly through online the preheater and the evaporator.
software systems, and can be started/shut down yy The hot organic fluid then expands in the turbine
easily through the online systems. converting the heat energy into mechanical energy.
The generator in turn converts the mechanical
energy into electrical energy.
System Operation
yy The hot organic vapour is then cooled in a heat
exchanger by water (mostly) and then condensed.
The ORC system operation is not only simple, but
The water here gets heated in the process and can
also almost identical to that of the SRCs. It can be
be used for various purposes as mentioned above
explained briefly as below:-
to increase the overall system efficiency.
yy An external fluid (from which heat is to be yy The cool organic fluid is pumped back into the
recovered) provides heat either directly to the regenerator to close the cycle.
organic (working) fluid of the ORC system or to a
thermal oil (that in turn heats the organic fluid) in

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

7
A geothermal power facility near El Centro, California (Photo by Warren Gretz / NREL , NREL No. 00430)
BUREAU OF ENERGY EFFICIENCY

Applicability
and industry
clustering
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

ORC technology has been widely used all the world waste heat or renewable energy. Figure 3 shows the
for nearly two decades or more, with more than 300 applicability of different type of ORC technologies at
units installed having a total capacity of more than different waste heat source temperatures. Typically,
2,000 MWe. These applications are not only for waste the Steam Rankine Cycles are used if the temperature
heat recovery, but also integrate various renewable of waste heat source is higher than 350C.
applications, such as the biomass and the geothermal
sources. An approximate potential of waste heat recovery
through the Organic Rankine Cycle technology can
The applicability of ORC technology varies with be estimated by using a simple graph (Figure 4).
the parameters of every energy source and needs The two parameters used for this estimation are the
to be customized for every installation. The major temperature (C) of the waste gas and the mass flow
parameter that determines the choice of technology, rate (kg/s).
is the temperature of the heat source, whether it is

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


400
Fluid Too many stages
STEAM
MICRO COGENERATION

stability limit High cost


SOURCE TEMPERATURE OC

300 SMALL ORC


HIGH
TEMPERTURE

200
MAINSTREAM ORC
POWER TOO LOW

LARGE ORC
100 LOW
TEMPERATURE

TEMPERATURE TOO LOW OTEC


(Ocean Thermal Energy Congervation

0
10 100 1000 10000
OUTPUT kWe

Figure 4: Estimating potential of power generation using ORC7


750 (kW)
700
650 2400
600 2200
2000
550 1800
Temperature(C)

500 1600
450 1400
1200
400
1000
350 800
300 600
250 400
200
150
100
50
0 2 4 6 8 10 12 14 16 18 20 22 24
Porttage gas (kgs)

10
Organic Rankine Cycle finds application in many Heidelberg Cement in Lengfurt, Germany in 1998 by
different industrial sectors that may be categorized in ORMAT TECHNOLOGIES, where the clinker cooler
to three major heads, namely: exhaust air at 270C served as a heat input to an ORC
system. After the successes of these installations,
yy Industrial waste heat recovery
many industries all over the world have used ORC
yy Internal combustion engines (ICEs) and Gas systems to convert their waste heat in to electrical
turbines energy. Some of these industries are Glass Plants,
yy Renewable energy power plants Thermal Oxidizers, Paint Ovens, Ovens, Brick Ovens,
Cement Processing, Ore Processing, Petrochemicals
etc.
a.Industrial waste heat
recovery8 A brief description of the applicability of ORC technology
in the most promising sectors is provided below:
In industries, there are plenty of waste heat fluids of
relatively low temperature that are dissipated to the Cement industry
environment, thereby wasting the thermal energy.
Some of these heat sources are reused in other on- Cement production process involves lime
site applications (thermal applications) or are used for decarbonisation reactions, that being endothermic,
district heating (not popular in India though). Thus, require huge amounts of heat and high temperatures.
when there is no direct application for this thermal The unused part of the heat supplied for these
waste heat, it could be used to generate electricity by reactions can be found in the combustion gas kiln
means of an ORC. gas (after the raw material pre-heating) and in the
clinker cooler air flow (an air stream used to cool
One of the first commercial waste heat power down the clinker after it exits the kiln). The waste
generation plants using the Organic Rankine Cycle heat in these flows could, via thermal heat recovery
was implemented by TURBODEN using the exhaust circuits, be the heat sources feeding the ORC system
gas from a Cupola Furnace in Torbole, Italy. During for power generation purposes.
the same time period, another plant came up at

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

Clinker Cooler Heat Boiler Waste ORC-Equipment Air Condenser


Heat Source Heat Recovery Power Generation Cooling - Process

Waste gas

Clinker Cooler Thermal Oil Pentane - Circuit Cooling - Circuit


Waste Gas Circuit

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

11
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

In India, typical cement production plants have Glass production processes can vary depending
production capacities ranging from 2,000 to 10,000 on the kind of product (float or hollow glass) or the
metric tonnes per day, with energy consumption fuel employed (methane, etc.) or the raw materials
ranging from 3.5 to 5 GJ per ton of clinker produced used or the production capacities etc. This makes it
(of which 10%-15% is in the form of electricity). difficult to develop a general rule of thumb to assess
the quantity of power that may be produced by ORC
As an indication, the power that can be produced by systems through waste heat recovery. However, the
an ORC system in a typical cement making process exhaust gas temperatures are relatively high (400C
can range from 0.5 to 1 MW per kiloton per day of - 500C), that may lead to high conversion efficiencies
clinker production capacity (assuming heat recovery (up to 25%) for ORC systems, with related economic
is happening from both kiln and cooler waste flows). advantages.
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 b.Internal Combustion Engines
cement plant.
(ICE) and gas turbines9
Iron and Steel industry Internal combustion (IC) engines and gas turbines
typically have thermal efficiencies in the range of
In steel production and processing industries, there 20 to 50%. A large part of the energy produced by
are multiple waste heat sources where energy combustion of the fuel gets dissipated in the exhaust
recovery with the ORC is possible. Some of these gases and jacket cooling. The exhaust gases often
sources include waste heat from rolling unit, forging have a temperature level above 300C, and thus,
unit, strip processing unit, heat treatment unit, are suitable as heat input sources for ORC systems.
blast furnaces, sinter, electric arc furnaces etc. The Also the hot air used in the jacket for cooling having
temperature range of exhaust gas from the reheating temperatures around 90C, can also be used or
furnaces (typically between 350C and 650C) enables integrated with an ORC system. In this manner, the
the use of thermal oil as a carrier for the organic heat total efficiency of the combined system (IC engine +
transfer fluids used in ORC cycles. ORC) can be substantially improved. Approximately
10% supplementary electric power can be generated
While waste recovery from clean gaseous streams
from the same fuel input.
in the industry is common, heavily contaminated
exhaust gases from coke ovens, blast furnaces, basic Another application of the Organic Rankine Cycle is to
oxygen furnaces, and electric arc furnaces that are use the waste heat from the gas turbines installed in
particularly used in this sector, continue to present a compressor stations for running huge compressors
challenge for economic waste heat recovery. that in turn maintain the pressure of these gases
flowing in the pipelines. By the end of 2009, within
Glass industry North America alone around 75.5 MW of waste heat
recovery plants of such type were commissioned at
Installations of glass manufacturing are divided into different compressor stations.10
two main types:
yy Plants for producing flat glass
yy Plants for producing hollow glass
c.Renewable energy power
plants11
Glass production involves melting and refining of
the raw materials, a process that takes place at high The ORC technology can be successfully integrated
temperatures requiring very high energy inputs. The into renewable energy power plants, such as solar,
unused heat supplied for glass production can be geothermal and biomass fired units.
found in the combustion gas exiting the oven, and this
gas can provide the required heat for the ORC system 9
ORCycle, Turn Waste Heat into Electricity by Using an Organic Rankine
Cycle, April 2011 http://www.orcycle.be/publicaties_bestanden/
to generate electricity (via an intermediate thermal Paper1_2nd%20ECP%20ORC_final.pdf
heat recovery circuit). ICF International, Status of Waste Heat to Power Projects on Natural Gas
10

Pipelines, November 2009


11
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

12
In solar thermal plants, solar energy is being is already applied for several decades to these heat
concentrated by parabolic troughs and used as sources. For low to medium temperature heat
an input heat source for a power cycle. The solar sources, the ORC is a favourable power generation
collectors can work at a temperature range of cycle. This is a widespread application in Germany
300C 400C. For a long time, this technology and in the rest of the developed world.
was linked to the traditional Steam Rankine Cycle
for power generation. However, since the Steam For biomass fired boilers, often an ORC i s preferred
Rankine Cycle needs higher temperature and a because of the lower operating pressure. The
higher installed power in order to be profitable, the condenser heat can be used in (biomass) drier
Organic Rankine Cycle that can work at much lower applications or for district heating.
temperatures especially during periods of low solar
radiation, offers a smaller equipment size and has A list of some of the most established companies in
good efficiency at such low temperatures. Utility the market and their technology range is provided in
scale solar thermal power plants is a well proven Table 1. Among these players, ORMAT has supplied
technology internationally. The parabolic dish, the a 4.2 MW waste heat recovery system based on ORC
solar tower and the parabolic trough are the three technology to the UltraTech cement plant in Andhra
major technologies that are used to generate power Pradesh in India.
in solar thermal technology.

Geothermal energy is widely available and offers a


broad range of temperatures, and the ORC technology

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


Manufacturer Applications Power Range Heat source Technology
temperature
ORMAT, US Geothermal, 200 kWe - 72 MWe 150C - 300C Fluid: n-pentane
WHR, solar
Turboden, Italy CHP, geothermal 200 kWe - 2 MWe 100C - 300C Fluids: OMTS, Solkatherm
Axial Turbines
Adoratec, Germany CHP 315 - 1600 kWe 300C Fluid: OMTS
GMK, Germany WHR, 50 kWe - 2 MWe 120C - 350C 3000 rpm Multi-stage axial
Geothermal, CHP turbines (KKK) Fluid: GL 160
(GMK) patented
Koehler-Ziegler, CHP 70 - 200 kWe 150C - 270C Fluid: Hydrocarbons Screw
Germany expander
UTC, US WHR, Geothermal 280 kWe > 93C
Cryostar WHR, Geothermal n/a 100C - 400C Radial inflow turbine Fluids:
R245fa, R134a
Freepower, UK WHR 6 kWe - 120 kWe 180C - 225C
Tri-o-gen, Netherlands WHR 160 kWe > 350C Turbo - expander
Electratherm, US WHR 50 kWe > 93C Twin screw expander
Infinity Turbine WHR 250 kWe > 80C 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

13
McNeil Generating Station at Burlington - a biomass gasifier operating on wood chips
(Photo by Warren Gretz / NREL , NREL No. 06356)
BUREAU OF ENERGY EFFICIENCY

Market potential
for ORC technology
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

As discussed in Section 2, ORC technologies find the manufacturing capacities and the possibility of an
applications in three major industry categories, ORC installation in a typical industry.
namely in waste heat recovery from industrial
processes, in waste heat recovery from internal
combustion engines and in renewable energy. This a.Market potential of ORC in
section provides an insight into such industries in Industrial processes
India and thereby, provides an assessment of the
energy that may be recovered and converted to
electricity by ORC systems. Cement Industry in India
The cement industry in India has seen a massive
Methodology used: 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
The current installed manufacturing capacity in every
30.92 million tonnes produced in 2010-11, followed by
industry segment was determined. The future capacity
Andhra Pradesh with 29.44 million tonnes and Tamil
additions till 2017 were projected using annual growth
Nadu with 20.63 million tonnes. The major cement
rates in the respective industry sectors. General
producers in India are ACC (13% market share)
thumb rules were determined for a typical size of the
followed by Ambuja Cement and Ultra cement with
industry. An estimate of potential of ORC technology
10% market share each.
for waste heat recovery was calculated correlating

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

Industry/application Unit Cement Float glass Steel: (rolling mill)


Kiln and clinker Oven exhaust Preheating oven exhaust
Heat source
cooler gas gas gas
Plant capacity Tons per day 2,500 500 6,000
Wasted thermal power in exhaust
MW 12.0 5.0 13.0
gasa
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)

16
Figure 6: State-wise cement production capacity in India as on 31st March 201112

State-wise cement production capacity in India (2011)

Rest of India, 15.17

Andhra Pradesh, 29.44


Gujarat, 12.19

Chhattisgarh, 8.63

Karnataka, 9.78
Rajasthan, 30.92
Orissa, 4.5

Uttar Pradesh, 7.05

Madhya Pradesh, 19.19 Tamil Nadu, 20.63

Maharashtra, 9.35

Projected Cement Production waste heat recovery plant using the Organic Rankine
Cycle. Based on this assumption and projected
The Centre for Science and Environment (CSE), Delhi manufacturing capacity of cement industry in India,
has projected the cement production growth in India a rough potential of the electricity production from
at a CAGR of 7.7%. The data shows that cement waste heat by ORC technology is estimated to be 574
production is likely to increase to 328 million MT by MW. To strengthen this assessment, one must also
2017. The industry has gone from being an energy note that there are 26 cement production plants in
intensive industry to one of the most energy efficient India registered under the CDM for their initiative
industries. to reduce carbon emissions resulting from their
processes, with 5 projects registered under the CDM
According to a study done by TURBODEN (one of the protocol for waste heat recovery for power generation.
market leaders in ORC technology), a 2,500 ton per
day plant of cement can be used to set up a 1.6 MW

Figure 7: Production capacity of Cement industry in India

Cement production capacity (Million tonnes per annum) in India


350.0 327.5
304.1
Million tonnes per annum

282.3
300.0 262.1
243.4
250.0

200.0

150.0

100.0

50.0
-
2012-13 2013-14 2014-15 2015-16 2016-17

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

17
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

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

Cumulative ORC potential for WHR (MW) in cement industry


700.0
574.2
600.0 533.2
495.0
Capacity in MW

500.0 459.6
426.8
400.0

300.0

200.0

100.0
-
2012-13 2013-14 2014-15 2015-16 2016-17

Table 3: List of WHR projects in Cement industry registered

Company WHR capacity Location Technology used Emission reduction


(MW) (tCO2 per annum)
Ultratech Cement 4 Andhra Pradesh ORC 16,871
Lanco Industries 12 Andhra Pradesh SRC 78,380
Limited
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

Glass Industry in India The total manufacturing capacity in India is currently


11,700 TPD with float glass having 4,700 TPD and
With over 12% annual growth, and almost 12,000 container glass having 7,000 TPD.
TPD of installed capacity, the glass industry is an
interesting and a high growth potential industry Float glass has emerged as the preferred flat glass
in India. More than a 100 years old now, with the product accounting for 90 percent of total glass
first manufacturing plant being set up in 1908, this consumption and is growing at a CAGR of almost 12
industry was classified as a cottage industry by the percent. The demand for float glass is expected to
Indian government for a long time. However, with grow at a CAGR of almost 12 to 15 percent over the
continuous surge in demand and a lack of capacity, next three to five years. The container glass industry
the industry has seen steady growth even in times of has been growing at 8-10 percent consistently and is
economic downturn. estimated at almost USD 1.1 billion.

The glass industry comprises of four key segments: Typically, a 500 ton per day glass manufacturing plant
hollow glass (mostly containers), flat glass, fibres and will have potential for a 1 MW Organic Rankine Cycle
special glass. Container glass is the largest segment waste heat recovery plant. The projected waste heat
that is witnessing strong demand from end user recovery potential through ORC in the glass industry
segments, such as liquor, beer, pharmaceuticals, in India is depicted in Figure 13 with a total potential
food, cosmetics etc. estimated at around 36 MW by 2017.

18
Figure 9: Projected glass production in India

Projected glass production (Tons/day)


Glass production (tons/day)

25000

20000

15000

10000

5000

0
2012-13 20113-14 2014-15 2015-16 2016-17

Float Glass Container Glass Total Production

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

Cumulative ORC potential for WHR (MW) in Glass industry


40.0
Million tonnes per annum

35.7
35.0 32.2
29.0
30.0 26.2
23.7
25.0
20.0
15.0
10.0
5.0
-
2012-13 2013-14 2014-15 2015-16 2016-17

Iron and Steel Industry in India14


India is the fourth largest producer of crude steel and the Working Group on Steel for the 12th Plan has
the largest producer of sponge iron or Direct Reduced projected the crude steel production capacity in the
Iron (DRI) in the world, and has one of the largest iron county to go up to 140 million tonnes by 2016-1715.
ore reserves in the world. As per the report of the
Working Group on Steel for the 12th Five Year Plan of Typically, a 6,000 ton per day steel rolling mill has a
India, the sector is projected to grow at a rate of 11- potential of generating 2.4 MW of electricity through
12% annually. an Organic Rankine Cycle waste heat recovery plant.
The projected waste heat recovery potential through
The National Steel Policy 2005 had envisaged steel ORC in the Iron and Steel sector is depicted in Figure
production to reach 110 million tonnes by 2019-20. 15 at a total potential estimated to be around 148.4
However, based on the assessment of the current MW by 2017.
projects, both the greenfield and brownfield ones,

Myiris breport, Hindustan National Glass & Industries Ltd, May 4, 2012:
14
Ministry of Steel, An overview of the steel sector, July 2012, http://steel.gov.
15

http://breport.myiris.com/skp/HINNATGI_20120504.pdf in/overview.htm

19
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

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

Iron and Steel production capacity (Million tonnes per annum) in India
160.0
Million tonnes per annum

135.4
140.0
120.9
120.0 108.0
96.4
100.0 86.1
80.0
60.0
40.0
20.0
-
2012-13 2013-14 2014-15 2015-16 2016-17

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

Cumulative ORC potential for WHR (MW) Iron and Steel industry
160.0 148.4
140.0 132.5
118.3
120.0 105.7
Capacity in MW

94.3
100.0
80.0
60.0
40.0
20.0
-
2012-13 2013-14 2014-15 2015-16 2016-17

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
b.Market potential of ORC countrys population dependent on it to meet their
energy needs.
technology in Renewable
energy The current availability of biomass in India is
estimated at about 500 million metric tonnes per
annum. The Indian Ministry of New and Renewable
Biomass Potential in India
Energy (MNRE) has estimated a surplus biomass
For an agriculture based economy, such as India, availability of about 120 150 million metric tonnes
biomass is an important energy source given the per annum that includes agricultural and forestry
benefits it offers. It is not only renewable, widely residues. This capacity of biomass corresponds to a
available, and carbon-neutral, but also has the potential of about18,000 MW of electricity generation
potential to provide economic upliftment of rural through the ORC systems.
areas by providing employment and access to clean
Apart from this, around 550 sugar mills in the

20
Figure 13: Cumulative capacity additions projected for Biomass power in India16

Cumulative capacity additions in Biomass power (MW)


2,500.00 2,300

2,000.00
1,700
Capacity in MW

1,500.00 1,280

880
1,000.00

440
500.00

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

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

Cumulative ORC potential in Biomass sector (MW)


2,500.00 2,208

2,000.00
Capacity in MW

1,632
1,500.00 1,228

1,000.00 844

422
500.00

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

country can produce an additional 5000 MW power Solar thermal power generation in India was limited
through bagasse based cogeneration, if they employ to some pilot projects and lab scale research and
technically optimal cogeneration technology. Out of development projects until the allocation of 500 MW
this potential, 3700 MW has been installed through of solar thermal power generation projects in the
Biomass combustion technologies, Non-bagasse first phase of the Jawaharlal Nehru National Solar
cogeneration and biomass gasifiers. Mission (JNNSM). Concentrated solar power (CSP)
or solar thermal technology also enjoys substantial
ORC technology readily finds application in all the allocation in the second phase of the national solar
above said biomass technologies except biomass mission (2013-2017).
gasifiers that constitute about 4 % of the installed
biomass power capacity in India. The mission targets to achieve 1000 MW of grid
connected solar plant capacity by 2013, around
Solar thermal power generation 9,000 MW by 2017 (3,000 MW by allocation under the
potential in India mission and 6,000 MW expected to come up due to
RPO obligations) and 20,000 MW to be achieved by
202217.
World Institute of Sustainable Energy, Achieving 12% Green Energy by
16

2017, June 2011 http://www.wisein.org/pdf/Final_12%25_RE_Report.pdf 17


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

21
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Figure 15: Cumulative capacity additions projected for solar thermal power in India18

Cumulative capacity additions in solar thermal (MW)


1,600.00 1,500

1,400.00
1,200.00
Capacity in MW

1,000
1,000.00
800.00
600.00 500

400.00
200.00
- -
-
2012-13 2013-14 2014-15 2015-16 2016-17

energy.

There are different technologies which can be used Since 96% of worldwide installed capacity of solar
to collect solar energy in the form of thermal energy thermal installations comprises of the Linear Fresnel
(heat energy). Table 4 below gives a list of all the technology and the Parabolic Troughs, it is assumed
solar thermal technologies and the global installed
Assuming second phase announcement in end of 2012 and equal capacity
19

capacity. It can be seen that Central Receiver Tower additions in 2014-15, 2015-2016 and 2016-2017
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

Table 4: Key features and worldwide installed capacity of solar thermal technologies
Technology Annual solar Practical Power cycles Commercial Worldwide
to electricity operating considered maturity installed capacity
efficiency temperature (mid 2010)
Linear Fresnel 8-10% 150-400C Steam Rankine, Organic Medium 8 MWe
Rankine

Parabolic troughs 12-15% 150-400C Steam Rankine, Organic High 943 MWe
Rankine
Central Receiver 20-30% 300-1200C Steam Rankine, Brayton Medium 38 MWe
tower (Gas turbine)
Parabolic dishes 20-30% 300-1200C Stirling Engine, Steam Low 1.5 MWe
Rankine, Brayton (gas
turbine)

mnre.gov.in/file-manager/UserFiles/mission_document_JNNSM.pdf
18
Assuming second phase announcement in end of 2012 and equal capacity
additions in 2014-15, 2015-2016 and 2016-2017

22
Figure 16: Cumulative potential of ORC technology in solar thermal industry in India

Cumulative ORC potential (MW) in solar thermal industry


1,600.00 1,440
1,400.00
1,200.00
Capacity in MW

960
1,000.00
800.00
600.00 480
400.00
200.00
- -
-
2012-13 2013-14 2014-15 2015-16 2016-17

that the solar capacity in India will also come up in


the same way.

Geothermal power generation potential c.Market potential of ORC


in India
technology in internal
Geothermal energy is the use of the earths inner heat combustion engines and gas
to generate useful energy. It is a clean, renewable and turbines
indigenous source of energy.
Internal combustion engines and gas turbines
India has the potential to produce 10,600 MW20 of
typically have a thermal efficiency in the range of 20
power from geothermal energy, although there are no
to 50%. In India, apart from the combined cycle power
operational plants till now. Geological Survey of India
plants, the gas turbines, the diesel generators and
conducted a study and has identified 400 medium to
the gas engines are used on a large scale for both
high enthalpy geothermal springs in India, clustered
commercial and industrial purposes. Mostly this is
in seven provinces, namely The Himalaya, Sohana,
used to generate power for captive consumption. A
Cambay, Son-Narmada-Tapi (SONATA), Bakreswar,
waste heat recovery technology would be economically
the Barren Islands and Godavari province.
feasible when utilized on a 24 x 7 hour basis, which
Geothermal energy can be used for both direct use may not be the case for most of these installations.
and power generation. In India, the direct use of In the commercial sector, many companies have
geothermal energy for various processes, such as installed vapour absorption machines to produce
drying, bathing and swimming, has been done on chilled water for air-conditioning using the waste
non-commercial basis till now. heat coming out from gas turbines/engines. A more
detailed analysis is required to estimate the potential
As of now there are no capacity additions which are of this sector with respect to ORC technology.
expected to come in geothermal energy in India in the
next two to three years excepting the possibilities of As of now, this sector is not considered in the
pilot projects, hence the potential of ORC technology estimation of overall potential of ORC technology.
in this sector is not considered in this study.

IBC Conference Geothermal Power Asia 2000, Geothermal Resources


20

of India, Feb 2000 http://www.geos.iitb.ac.in/geothermalindia/pubs/IBC/


IBCTALKweb.htm

23
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

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.

Figure 17: Share of ORC potential in different industry sectors

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 Energy c
-
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 JNSSM
b Capacity additions during 2012-2017 have been accounted
c There are no market developments in this sector in India
d 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

24
BUREAU OF ENERGY EFFICIENCY

Regulatory
Support for Waste
Heat Recovery
Technologies
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

History of Waste Heat Recovery electricity is INR 0.20 (EUR 0.003). It also has high
energy efficiency as it not only has no water or fuel
in India requirements, but also uses the easily available
organic fluid, iso-pentane, as the working fluid in the
The Clean Development Mechanism (CDM) was ORC system. This results in a saving of INR 80 million
introduced during the Kyoto Protocol, signed on 11th (EUR 1.2 million) every year on the cost of power
December, 1997. The protocol was a binding obligation generation.21 Thus the introduction of the ORC has not
signed by member countries of the United Nations, only made the production cycle more energy efficient,
under the United Nations Framework Convention on but also has also helped reduce the operational costs
Climate Change (UNFCCC), and obliges the signatory by reducing the energy costs. In addition to this,
countries to reduce their greenhouse gas emissions the company can trade the CERs issued to them to
by 5.2% during the period 2008-2012 against the generate further revenues.
baseline emissions in the year of 1990. Projects
registered under the CDM mechanism receive The five exchanges trading in carbon credits are
tradable Certified Emission Reduction (CER) credits the European Climate Exchange (ECX), NASDAQ
for every tonne of Carbon-dioxide (CO2) equivalent OMX Commodities Europe, PowerNext, Commodity
emission reduced. India currently has more than 60 Exchange Bratislava and the European Energy
projects using waste heat recovery systems that are Exchange (EEX). Figure 22 shows the fluctuations in
registered as CDM projects. the daily spot prices of the CER futures on the ECX
between January 2010 and October 2012. The prices
In India, the first waste heat recovery (WHR) project or CER futures has fallen steadily over the past years
using Organic Rankine Cycles (ORC) that was from a high of INR 889.2 (EUR 13.68) in January 2010
registered with the CDM, was by Ultratech Cement, in to a low of INR 145.60 (EUR 2.24) in October 2012 to
March 2007. The projects annual emission reduction less than INR 80 (EUR 1) as of December 2013. 22This
was 16,871 tonnes of CO2-eq. The cement industry is rapid and sharp fall in prices from July 2011 raises
traditionally known to be high on energy consumption questions regarding the relevance of the CERs in the
and low on energy efficiency. The ORC at Ultratech future, and thus the CDM is no longer considered a
Cement has a capacity of producing 4.8 MW of functional incentive scheme. If the fall in prices of the
electricity and meets 10% of the power requirement CERs continues, industries will not be incentivised to
of the cement plant. The cost of generation of reduce their emission reductions through CERs.

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

20
Setting Price...
15

10

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

21
Ultratech Cement, Andhra Pradesh Cement Works http://www.
ultratechcement.com/images/downloads/sustainability_resources_APCW.
pdf
22
European Energy Exchange, Emission Rights, CER Future, October 2012
www.eex.com/en/

26
Present Regulatory Scenario a targeted amount of energy reduction for these
DCs between 2012 and 2015. The DCs will be issued
and Fiscal Incentives for Waste Energy Saving Certificates (ESCerts) for every tonne
Heat Recovery of oil equivalent energy that they save over and above
their respective targets. These ESCerts can then be
The National Action Plan on Climate Change (NAPCC) traded on the Indian Energy Exchange (IEX) or on
of India brought eight national missions in 2008 in the Power Exchange India Limited (PXIL). DCs who
order to reduce the effects of climate change in the have failed to achieve their targets, can avoid being
country. The National Mission for Enhanced Energy penalized by purchasing ESCerts, amounting to the
Efficiency (NMEEE) is one amongst the eight missions shortfall in their target achievement. The issuing
of the NAPCC. The Government of India in 2002 set of these certificates shall be reviewed on a case by
up the Bureau of Energy Efficiency (BEE)23 under the case basis by the BEE or the MOP. The scheme, with
Energy Conservation Act (EC) of 2001. The BEE was its tradable energy certificates hopes to improve the
set up to structure policies around promoting energy cost effectiveness in promoting energy efficiency. The
efficiency in the Indian economy. One of the primary target for 2014-15 is to reduce energy consumption in
mandates of the BEE is to regulate the NMEEE, along the specified industries by 4% from the base year of
with the Ministry of Power (MOP). 2009-10. Table 6 gives the targets under the scheme
for cycle 1 (2012-2015) for every DC sector.
The NMEEE has four constituent schemes, as shown
below, of which the PAT scheme is the one applicable Since Waste Heat Recovery (WHR) finds application
for the Waste Heat Recovery initiatives. in most of the DC sectors, the DCs can reduce their
annual consumption of energy and increase their
yy the Perform, Achieve and Trade (PAT) scheme
energy efficiency by implementing such technologies.
yy the Market Transformation for Energy Efficiency
(MTEE) scheme
Other Regulatory Initiatives
yy the Energy Efficiency Financing Platform (EEFP)
yy the Framework for Energy Efficiency Economic The Cement Manufacturers Association (CMA) had
Development (FEEED) petitioned the Government of India during its pre-
budget meeting to include some incentives and
Perform, Achieve and Trade: The EC Act has
subsidies to bring the cement industry in the country
specified a list of Designated Consumers (DC)
at par with the other core infrastructure industries.24
consisting of the aluminium, cement, chlor-alkali,
One of the core energy efficiency measures taken
fertilizer, pulp and paper, thermal power, iron and
by cement manufacturing units is the waste heat
steel, and textiles industries. The EC act specified

Table 6: Cycle 1 targets under the PAT scheme


Sector Min. annual energy No. of DCs Energy Saving Targets under PAT
consumption for the DC (toe) between 2012-2015 (million toe)
Aluminium 7,500 10 0.456
Cement 30,000 85 0.816
Chlor-alkali 12,000 22 0.054
Fertilizer 30,000 29 0.478
Iron and steel 30,000 67 1.486
Pulp and paper 30,000 31 0.119
Textile 3,000 90 0.066
Thermal power plant 30,000 144 2.211
Total 478 6.682
Source: PAT, Ministry of Power 2012; BRIDGE TO INDIA analysis

The Economic Times; Budget 2012: Levy uniform and specific rate of
24
23
Bureau of Energy Efficiency http://www.beeindia.in/ excise duty on cement says CMA; Feb 23rd 2012

27
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

recovery. But the initial costs of setting up a waste heat under the North-Eastern Industrial and Investment
recovery system, especially an ORC, is between INR Promotion Policy (NEIIP-2007) to implement such
81 million (EUR 1.2 million) and INR 108 million (EUR energy efficiency measures. If these factories fail to
1.7 million) per Mega Watt.25 This is almost at par with set up the waste heat recovery systems, they will be
the capital expenditure involved in setting up a plant ineligible for all these incentives and will be put on a
of similar capacity based on renewable sources of negative list under the NEIIP policy. The coking coal
energy, such as wind, solar, biomass, or small-hydro. plants have high heat generation from the furnaces,
The CMA has petitioned the government to consider and are therefore, ideally suited to adopt the waste
waste heat recovery as a part of renewable energy heat recovery systems. However, if stringent penalty
sources. Renewables currently receive incentives, measures are not taken for non-compliance, then it
that include preferential tariffs for sale of electricity might be difficult to bring energy efficiency measures
generated, accelerated depreciation benefits, into an industry that has so far has had no economic
generation based incentives, capital subsidies, import or regulatory incentive to promote them.
duty exemptions, tax exemptions and research and
development support amongst various others. In 2010, the Ministry Of Power (MOP) of the
Government of India set up the State Energy
The Biomass Power and Cogeneration Programme of Conservation Fund (SECF) under section 16 of the EC
the Ministry of New and Renewable Energy (MNRE) Act of 2011. The total amount dedicated to this fund
have incentivised the usage of ORC systems in from 2010 to 2012 was INR 700 million (EUR 10.8
biomass and cogeneration plants. Any plant under million). The funds are disbursed by the BEE. The
this programme can avail of an 80% Accelerated initial disbursement carried out by the BEE was for
Depreciation benefit on the purchase of the ORC a total of INR 173 million (EUR 2.7 million) during the
systems, thereby reducing the high initial capital financial year 2009-10. Table 7 gives the state wise
costs of setting up an ORC system. breakup of the distributed funds. This initiative by the
MOP encourages the adoption of energy efficiency
As per the Power Minister of the state of Assam, Mr. methods at the state level, thus ensuring more
Pradyut Bordoloi, the state is planning to formulate a targeted efforts.
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

Table 7: Funds disbursed by the BEE under the SECF


State Amount millions(INR) Amount (EUR)
Nagaland 12.5 1,92,308
Haryana 20 3,07,692
Punjab 20 3,07,692
Rajasthan 20 3,07,692
Kerala 20 3,07,692
Andhra Pradesh 20 3,07,692
Tamil Nadu 20 3,07,692
Karnataka 20 3,07,692
Chhattisgarh 20 3,07,692
Source: Ministry of Power, Govt. of India

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 r g 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

28
BUREAU OF ENERGY EFFICIENCY

Waste heat recovery


projects at Glass
Manufacturing
Facilities in India
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Saint Gobain Glass India Limited (SGGI) is a 100% capacity of 800 tonnes per day. The waste heat emitted
owned subsidiary of Compagnie de Saint-Gobain from the float line is used to generate steam, which in
in France, the worlds largest manufacturer of flat turn rotates the turbine, thus generating electricity.
glasses. It has an Indian manufacturing unit in
Sriperumbudur district of Tamil Nadu. The plant Apart from the above described waste heat recovery
manufactures various types of flat glass using the project, another glass manufacturing company Asahi
float glass manufacturing process. The plant houses Glass India Ltd, has installed a waste heat recovery
two Float Lines, two automotive glass processing system to recover the heat available from the flue
lines, a 5 million sq. metre mirror processing line and gas of the existing fuel oil fired Glass Furnace in its
a coater facility, all of which are in a 175 acre facility. manufacturing facility situated in Maharashtra, India.
The waste heat recovery plant is based on a steam
The processes mentioned involve large amount of rankine cycle and helps in reducing 10,408 tonnes of
waste heat that was being expelled in the atmosphere. CO2 emissions from the facility27. This project is also
To curtail the environmental impact from its facility, registered with the UNFCCC as a CDM project.
SGGI has installed a waste heat recovery boiler in the
flue gas stream to convert this heat into steam. This is Apart from the savings caused by the in-house
the first and only kind of waste heat recovery system electricity production, the only additional source of
installation in the glass industry in India. This project revenue to sustain these projects is the PAT scheme,
is registered with the UNFCCC as a CDM project, and especially since the CDM is quite non-functional.
it helps to reduce about 7,800 tons of CO2 emissions Following section describes the major challenges
from the atmosphere. faced by the Indian industry to incorporate waste heat
recovery systems in their operations.
Out of the two float glass lines, the heat recovery
boiler system is set up in float line no. 2 that has a

Table 8: Technical parameters of the WHR at SGGI26


PARTICULARS DETAILS
Capacity 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 430C
Exhaust gas outlet temperature 250C
Steam quantity 7,600 kg/hr
Steam pressure 390C
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

UNFCCC Project Design Document, Power generation from flue gas waste
26 27
UNFCCC Project Design Document, Fossil Fuel switch project at Asahi
heat, Tamil Nadu, October 2012, http://cdm.unfccc.int/Projects/DB/TUEV- India Glass Ltd, Taloja, Maharashtra, India - http://cdm.unfccc.int/Projects/
SUED1265724642.95/view Validation/DB/J5LPBWBFNEM97CGET17WOGHH90BBTW/view.html

30
BUREAU OF ENERGY EFFICIENCY

Indian Industry on ORC:


Approach paper and
Case Study by Thermax
India Limited
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

INTRODUCTION True challenges of waste-heat become more evident


when the temperature levels go below 450C and/
or quantity of the waste heat falls below 10 million
Waste Heat by definition is the ultimate heat rejected
kcal/h. The most obvious challenge is due to the
by any process in which options of all the heat that can
lower efficiency of energy conversion devices at
be internally used, is exhausted, and any further use
lower temperature levels coupled with high cost of
may not be economically viable. Waste heat emitted by
heat recovery at such low temperatures. Besides
the process is based on the optimization of resources
this, the power generation systems for such medium
and is, therefore, strongly dependent on economic
waste heat streams pose limitations in the design
parameters. The quantity and quality of waste-heat
and manufacturing of the prime movers and, hence,
varies depending on the nature of the process and
result in high cost. Therefore finding an economically
optimization algorithm used by the respective process
viable solution for such waste heat to power
licensees.
generation system requires, a multiple approach both
Waste heat can be effectively used as heating energy at technological level as well as at the policy level.
(steam) and for cooling (air-conditioning by vapour Fortunately the technological advances in the new
absorption) if there is a scope for such a usage. power cycles have made it viable to explore alternate
Effective utilization of waste heat for cooling and options in this segment of the waste heat to electricity.
heating, although economically attractive, calls for
There is yet another segment of waste heat which
proximity of user points that can utilize this energy.
is emitted at lower than 100C and this requires a
This becomes a bottle neck in many instances.
different treatment. This is kept out of the scope of the
Hence, the conversion of waste heat to electricity
current ambit. It can be safely assumed that 90% of
becomes one of the most suitable options in this
waste heat belongs to the medium category, i.e. less
space of waste heat to energy solutions. Electricity
than 300C and/or about 10 million kcal/h. Merely
generation can be monitored, fed into the grid and
extrapolating the conventional solution available
also incentivized in a most rigorous manner. The
at the high temperature and high quality will not
major challenge, however, is the technology needed
address this situation, since most of the waste-heat
for conversion of waste heat to electricity. Waste heat
coming from the processes is in this range, and in
at temperatures in excess of 450C and in sufficiently
this range the conventional solutions are not optimal
high quantity (>15 million kcal/h or about 5 MWe)
solutions. Hence, the need of the hour is to address
makes power generation from such waste-heat
this segment with complete focus and concentration,
system economically viable. This is due to the fact
since any solution in this segment will impact large
that such conversion systems have their replica in the
number of industrial processes from small scale to
fossil based power plants using Steam Rankine Cycle
large scale enterprises. This will also result in saving
(SRC). SRC having proliferated itself as viable heat to
of substantial quantity of fossil fuels that are playing
power generating option can, therefore, be used in
havoc in the Indian economy due to the current
waste heat to electricity applications when the quality
account deficit issues mainly due to the increased
of waste heat matches close to the fossil energy
cost of crude oil import.
systems or the quantity is enough for generating
electricity in excess of 10 MW scale.

The major challenge, thus, lies when the waste ISSUES RELATING TO THE
heat quality and quantity becomes lower than what EXTRAPOLATION OF SOLUTION
is stated above lets call it as medium waste heat USING STEAM TURBINE BASED
systems and this medium waste heat is the most
typical waste heat which needs a different approach.
SYSTEMS
This is given in the following sections.
Steam turbines are intrinsically designed for high
power capacity. There is a fundamental aero dynamic
CHALLENGES IN THE MEDIUM basis for this. The cost per kW of steam turbine is
highly functional of the MW rating of the turbine due
WASTE TO HEAT POWER to the design limitations of the steam turbines for
GENERATION SYSTEMS lower capacity systems. To give an example, a 10 MW
range turbo-generator costs about INR 7,500 per kW

32
(approximately INR 7.5 million per MW). However, the advantage in these advanced cycles is the lower
turbo-generators at 1 MW scale cost about INR 35,000 water consumption, and these cycles can be coupled
per kW or INR 35 million per MW, and the cost goes with vapour absorption cooling systems as well to
up exponentially over INR 100,000 per kW or INR 100 make them water free without any compromise on
million per MW at 50 kW scale. The reason for this is the efficiency due to the air cooled systems. Such
both technological as well as of economy of scale. A power plants based on organic fluids will be the most
turbo generator that costs INR 35 million per MW, attractive option that needs to be explored seriously
when coupled with waste heat recovery systems and in India.
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. OTHER INNOVATIVE SOLUTIONS
Below 1 MW scale, the numbers become much IN WASTE TO POWER SYSTEMS
more challenging and hence feasibility is practically
impossible. Another major component in the waste heat to
power scenario is heat recovery devices. Currently
Steam turbines and waste-heat systems are fairly
these heat recovery devices are designed in a very
matured in terms of technological development
conventional manner using standard materials. Due
and, thus, further scope of reduction in cost is
to low pressures, there is a high potential to use
rather limited. Hence, the only feasible solution is to
much lighter weight materials, and also need to be
move away from the steam cycle and to explore the
investigated thoroughly to reduce material content,
alternate options.
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
WHAT IS PROPOSED heat transfer extended surfaces that enhance the
waste heat transfer to the secondary fluids.
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
NEW MODEL REQUIRED FOR
heat to power attractive not only from an efficiency FASTER PROLIFERATION
point of view, but also from a financial one. A very OF WASTE HEAT TO POWER
fundamental level analysis indicates that moving TECHNOLOGY IN INDIA
away from the SRC to other Rankine Cycles, such
as the Organic Rankine Cycle and/or the Organic The above discussions indicate that the for waste-
Based Hybrid Cycles (Rankine plus Brayton), would heat to power recovery based on steam cycles, will
bring feasibility in this range over a period of time. not yield the desired results, and hence new cycles
Further, these cycles enable higher system efficiency mentioned above with appropriate cost reduction
and more compact equipment. The shift from steam measures for the waste heat recovery devices, must
based cycles to other fluids based cycles implies the be developed. These devices can generate electricity
use of fluids of lower density resulting in much lower from waste heat sources of temperatures 350C to
equipment size at lower operational temperature as low as 140C, and have capacities ranging from 1
ranges. The direct consequence of this is the usage to 3 MW scale to 50 kW scale. These systems can be
of lower material content per kW of power generated. then used in not only waste-heat recovery to power
Ideally a 300C flue gas generating 1 MW power conversion from the currently identified sectors, such
through a steam cycle would use, say, 25 kg of steam as Cement, Steel, Fertilizers, Glass and Aluminium,
per kW while an equivalent Organic Rankine cycle but also can be used in many applications in small to
would use less than 4 kg per kW. Therefore, there medium scale sectors as well. So much so that such
is a strong basis for the shift. Besides this, design development can become ubiquitous, and hence can
based on screw expanders or even on simple internal be multiplied on a large scale in India. This is the only
combustion engines, greatly reduce the cost of the way that waste heat to power systems can proliferate
equipment. Further these cycles present themselves in India.
to multiple level innovations and offer themselves
to much higher efficiency possibilities. One more

33
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

It may be worthwhile to mention that when screw development while inspiration can be taken from what
compressors for air-conditioning purposes were is happening in the other parts of the world.
introduced, there were reservations of accepting
the alternate option mainly due to very high capital The strategy, therefore, should be multipronged. Like
costs. However, as the technology became popular in many instances of introduction of new technologies
and the number of installations multiplied, the costs be it solar or wind energy, where the state invested
have drastically come down, and today more than in the early development phase to trigger the
90% of the compressors used in the air-conditioning further proliferation using many instruments at its
industry are based on screw compressor technology. command the waste heat to power also calls for
Fundamentally, screw compressor technology is similar developments to be carried out. An initial
superior to the conventional reciprocating by its phase of development is needed when technology
very nature. There is a similarity between this and demonstration needs to be carried out based on
the proposed Organic Rankine Cycle based screw a dedicated research and development as well as
expander development that is one of the critical pilot scale demonstration units followed by initial
components in this new waste heat to power deployment based strategies.
technology domain.
The first and foremost step needed is, therefore,
One more analogy that can be given is that of the demonstration of this new concept in a number of
diesel engines which are sold in large numbers both facilities where such concepts are well suited for
in MW and in kW capacity ranges. Cost per kW of demonstration. One can choose to demonstrate
diesel engine varies within 20% range between kW at 50 kW scale, 300 kW scale and at 1 MW scale,
range and MW range. Clearly this is because of the choosing the representative waste producing
market proliferation, and hence the resultant cost industries for such demonstration in different parts
optimization. In a similar way, the Organic Rankine of the country. The demonstration may total up to 5
Cycle and the Hybrid Cycles would also become MWe with investment in research and development,
popular due to their intrinsic lower material content testing and pilot technology development and
and are sure to become cheaper than the conventional manufacturing limited to INR 1 billion (12.50 million
steam turbines in the near future. Also the cost per Euros). These initial demonstration projects must
kW would remain almost in the same range both in be 100% funded by the government through many of
kW and in MW capacities. the mechanisms available from the Indian Ministry
of Science & Technology, Indian Ministry of Power
The new technology for waste heat to power and Indian Ministry of Heavy Industry (MHI) using
conversion would, therefore, be based on the funding available from National Clean Energy Fund or
advanced Organic Rankine or Hybrid Cycles using the National Innovation Fund Mechanism etc.
improved waste heat recovery exchangers and new
cycles integrated with systems that use less water in Technologies needed for this should be indigenously
the power cycle. The ranges can be at 1000 kW, 300 developed, and competent technology players may
kW and 50 kW scales with target parameters on cost, be enrolled to participate during the demonstration
space, water consumption and availability factors. phase. Such demonstration phase should be
These can be bench marked, and all the developments completed in the shortest period of time, say about 2
must shoot to reach the target values in a time bound years, and then one should move to the next phase
manner. where industry may invest 50% of the funds needed,
and the rest of the 50% of the funds will come from
the government.
POLICY LEVEL INTERVENTION
The premise here is that from Phase 1 to the next
NEEDED FOR MAKING WASTE TO phase sufficient experience would have been gained
POWER A REALITY IN INDIA and would attract many other industries to adopt and
participate in further development of these systems.
Waste heat to power is restricted to only the industrial The cost will still remain high since the economy
segment in the Indian market, and hence needs of scale would not have kicked-in at this stage, and
different instruments for proliferation in the country. hence would require this support for some more time.
There is a need for an India centric technology

34
Phase 2 would, therefore, have to run for 5 years or very near to economic viability. A small boost from
where sufficient number of systems would get built policy and regulatory respects, would increase the
in the waste-heat landscape of the country. During conversion of waste heat to power by many folds. It is
this phase, the government contribution can be suggested that waste heat to power should be treated
slowly reduced from 50% to a much lower value as alike Renewable Energies, since the former is carbon
the economy of scale would bring down the cost of neutral, and many a times not dependent on fossil
the system as well. With this, the mechanism would fuels. In fact, this may also help reduce the issue of
become self-sustainable in due course of time, and supplying more energy to the industries by reducing
will be able to proliferate itself without any external their energy consumption, as well as supply the
support. The Phase 2 may boost up from the 5 MW electricity not only to the industry but also to the local
demonstration phase to 50 MW initial deployment community, thereby boosting the off-grid electricity
phase. This will then set up the pace for full-fledged supply market in the country.
multiplication of the systems in the waste heat to
power ecosystem. Once the advance cycles, described above, completes
the phase two program, small boosters mentioned
For high temperature large quantity heat recovery, above for the conventional cycles would make waste
conventional steam turbine based system is already heat to power highly popular and also save precious

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

Waste Heat to Power

Large quantity high Low temperature


temperature waste waste heat

Conventional Advance
steam turbine technology
route development

Phase 1 Late Phase 2


on
Treatment at Increased 100% funding Industry & GOI
par with order of Merit by GOI up to 5 combined
Renewable Power for Evacuation Mwe demonstration investment up to
plant 50 Mwe plant

Treatment at par with Renewable


Power & Increased till the technology
gets fully developed

35
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

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

16

14

12

10
Price Cr/Mw

6
No support
4 required

0
0 1 2 3 4 5 6 7 8 9 1 0
Numberofyears
viabilitylimit Conventionalcycle NewCycles

foreign exchange for India from being spent on yy Medium quality waste heat meaning process
importing fossil fuels. For the Advance Cycles, the streams or waste streams with temperatures less
boost can be for a limited time as after a certain than 300C and with heat in quantity equivalent
period (when technology gets fully developed), the to 10 million kcal is the most challenging waste-
price per unit of power generated will be same or heat to power solution. Current steam based cycle
fall below that of conventional steam based power that is acceptable to waste heat above 450C is not
generated from waste heat. suitable for this range.
yy The medium quality range should vary from 50 kW
Figure 24 gives above recommendation pictorially. to 1 MW scale.
Figure 25 gives an expected time lines and time till yy Organic Rankine Cycle or Organic Hybrid Cycle are
the boosts from the policy and the regulatory support the most appropriate options in this range.
are required. yy Small boosts of considering waste heat to power
at par with renewable energies and an increased
The figure above shows the cost reduction trajectory merit order for power evacuation would make this
for the new cycle in waste heat to power compared concept very popular in the Indian Industry. For
to the conventional cycles. Clearly the viability mark new cycles later on, this will not be required.
can be breached by the new cycles if the phase 1 and yy Specific material used (i.e. kilogram of steel per
phase 2 strategy proposed above, is implemented kW) makes organic based systems, the ultimate
properly in the country. cost effective solution, once sufficient numbers
are needed in the industry.
yy Innovative design of the waste heat exchanger
CONCLUSIONS including lower thickness and profile surfaces
yy Waste heat to power is the most flexible way to would make the balance of plant also less
recover energy from waste heat after the internal expensive.
recovery of the heat is carried out within the yy Organic cycle can be designed with waterless
process itself. solutions and added on with attractive features.

36
yy Demonstration scale plants are needed initially the Government of India in village Shive near Pune
to identify suitable industrial sectors supported city in the state of Maharashtra. The plant, using the
by the government funding for such projects. The Organic Rankine Cycle technology, was implemented
total demonstration phase development may be by Thermax India using the steam generated from
limited to 5 MWe. the medium temperature parabolic trough solar
yy Subsequent proliferation to 50 MW scale will go collectors during sunny days in hybrid mode using
through partial funding. Over a period of time biomass support during low radiation hours. The
the funding will taper off till the industry system medium temperature solar collectors produce
becomes self-sustainable. This is assumed to be thermal energy in a cost effective manner and the
over a period of five years. same is converted to power in the most efficient way.
yy Such a development will bring in a virtuous The 125 KW ORC system is operating from 110 kW to
cycle in every quarter of the society from the as low as 30 kW capacity to meet varying demands of
technology sector to the manufacturing sector. the village for agriculture pumps.
The savings in fossil fuels will be enormous once
Also the plant has demonstrated that ORC can also run
this development triggers low cost manufacturing
in India. 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
CASE STUDY over 2 years now in a rural environment. It has proved
that ORC is the most suitable technology for solar
One of the first demonstration units for generation power generation in hybrid and poly generation mode.
of power using ORC in distributed mode using In addition, Thermax India has installed another ORC
Solar Biomass hybrid concept is commissioned by unit at the Indian Institute of Sciences (IISc) campus
Thermax India in December 2011 with the support at Bangalore in Karnataka, India for research and
from the Department of Science and Technology of 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.

37
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Figure 21: In house test installation at Thermax R&D center for experimentation and
development purposes installed in 2010

Photo by Thermax India Ltd.

Figure 22: ORC Plant manufactured by Thermax for IISC Bangalore for research and
academic purposes

Photo by Thermax India Ltd.

38
BUREAU OF ENERGY EFFICIENCY

German Industry on ORC:


Approach paper and
Case Study by DRR
Cyplan Ltd.
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

The Stadtwerke Gro-Gerau Versorgungs-GmbH Figure 23: ORC system in Gro-Gerau


(GGV) municipal utility company has invested in an
energy-efficient Organic Rankine Cycle (ORC) system
from Drr 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 Drr 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 companys
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 Photo by Drr Cyplan Ltd.
Celsius (40C) to ensure ideal living conditions for
the microbes responsible for the fermentation and The ORC system is simple, robust and easily
outgassing processes. During the summer, the heat is integrated into the overall system. Since there is no
also used to dry herbs in a neighbouring agricultural complex intermediate circuit and no separate turbine
operation. The concept, thus, corresponds to the lubrication with lubricating oil, the system operation
fundamental idea of combined heat and power (CHP), is also very stable. The ORC system uses the flue-gas
according to which the energy is simultaneously heat throughout the year and also produces full power
converted to electrical power and heat and used, in the summer, thanks to the high condensation level.
says GGV Managing Director Paul Weber.

ECONOMIC EFFICIENCY
DRR ORC TECHNOLOGY
This investment has been worthwhile for the
The integration of the ORC system from Drr, Stadtwerke Gro-Gerau municipal utility company.
the system construction specialist, enhances The integration of the ORC system permitted the
comprehensive the energy utilization. ORC stands exhaust-air heat exchanger behind the CHP unit to
for Organic Rankine Cycle a procedure that be omitted. The total electrical power generated
uses waste heat to produce electricity with the aid is increased from 8.3 to more than 8.7 million kWh.
of an evaporation process. In Gro-Gerau, the high- This allows electricity to be provided to around 360
temperature flue gas waste heat from a CHP unit or more end-users. Despite the omission of the
with an electrical output of 800 kWe is used for this exhaust-air heat exchanger, the heat is fed into the
purpose. This proven principle produces 60 kWe of heating network and is fully available for herb drying
additional power on average, explains Drr project and for heating the administration building, the
leader Timm Greschner. No heat is lost in the fermenter and the post-fermenter. The amortization
process, no matter whether or not a concept for heat period of such an ORC investment is five years with
utilization exists. Up to 18% of the total heat in the an electricity buyback price of 20.3 Euro cents/kWh
flue gas is converted to electricity, and the remaining and 7,500 hours of full utilization. With a depreciation
(approx. 82%) is provided at a temperature level of up period of ten years, this corresponds to an internal
to 90C. A significant efficiency increase in power rate of return of 15.6%. The use of ORC technology
generation has, therefore, been realized in Gro- perceptibly increases the CHP remuneration.
Gerau without restricting the existing heat utilization According to the recommendation from the clearing
concept. office for the German Renewable Energy Law dated

40
Figure 24: The flow chart schematically shows the system integration after the ORC
expansion

800 kWel

60 kWel
Biogas System

CHP ORC

Biogas Flue gas

Heating network 900C

Heating of buildings
Dryer for herbs

November 25th, 2010, Systems with heat extraction engines and waste-heat sources. Waste heat is one
() are to be considered as a unit for the purpose of of the largest unused potential sources of energy in
determining the power to heat ratio if a device is used Germany, explains Frank Eckert, Managing Director
to convert the extracted heat into electricity by means of Drr Cyplan. Waste heat from industry, firing
of an additional generator. Consequently, the power systems, and the use of geothermal heat sources
to heat ratio of the overall system consisting of a CHP are especially attractive application options for ORC
unit and an ORC improves according to the formula technology, which assists in developing energy-
below. efficiency potentials as well as attractive returns on
capital.
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 ABOUT DRR
the remuneration automatically rises when the
power to heat ratio is increased by the ORC system. Drr is a mechanical and plant engineering group that
With unchanging heat utilization, the CHP income holds leading positions in the world market in its areas
increases by 17.6% with a retrofitted CHP unit. In of operation. It generates more than 80% of its sales in
the case of heat utilization with a dryer (e.g. a wood, business with the automotive industry. It furthermore
digestate or herb dryer) of 1.5 million kWh/a, the supplies the aircraft, machinery, chemical, and
resulting additional CHP income is around 7,100 pharmaceutical industries with innovative production
Euros per year. and environmental technology. The Drr Group
operates in the market with four divisions: Paint
and Assembly Systems plans and builds paint shops
OTHER APPLICATIONS and final assembly plants for the automotive and
aviation industries. Application Technology provides
Beyond the use in CHP concepts, ORC systems from the automatic application of paint, sealants and
Drr are suitable for a broad range of applications. adhesives with its robot technologies. Machinery and
The energy-efficient technology from Drr generally systems from the Measuring and Process Systems
can be coupled with the most diverse combustion division are used in balancing and cleaning, in engine

41
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

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. Drr employs approx. 7,300 people at
over 50 locations in 23 countries worldwide. In fiscal,
2011 Drr 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.

42
BUREAU OF ENERGY EFFICIENCY

Challenges for waste


heat recovery projects
in India and the way
forward
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Even though there have been a number of projects in viabilities have never really been fully explored.
various Indian industries that employ the waste heat
recovery methodology of the CDM, the potential of 6. The flue gas generated from the furnace in the
waste heat recovery is still not fully tapped. Some of glass industry has significant amount of corrosive
the reasons for this potential not being tapped fully components, such as SOx and NOx, dust and
till now are: traces of chlorides, fluorides and metals, present
as impurities in the raw materials. This reduces
1. The waste heat from cement plants has a lower the service life of the waste heat recovery system
temperature than the waste heat from many leading to higher operating and maintenance costs
other industries, such as iron and steel. Since of such systems. More capacity building efforts
traditional steam power cycles need high waste must be taken up for the technicians
heat temperatures, these technologies have not
penetrated much in the sector. On the other hand 7. Since the waste heat recovery systems are directly
this is an opportunity for the Organic Rankine Cycle coupled with the manufacturing processes, any
technology that utilises such low temperature operational failure in such system leads to system
waste heat, but the full potential of the technology downtime, thereby, causing production losses.
is yet to be demonstrated for mass adoption. This also has caused many of the industries to
shy away from installing such systems, a fear that
2. The waste gases from many industries contain can be removed if more manufacturers of these
large amounts of particulate material that need systems come in direct contact with the customers
to be removed before feeding them to the boiler to show the systems have functioned in difficult
or heat recovery units. This leads to a higher cost conditions over years without any issues.
of power generation, reducing the feasibility of the
projects in many cases. The potential of using ORC technology in India,
assessed above, is thus approximately 4,406 MW
3. Non-availability of technology within the country out of which 758 MW can be installed in just three
is another major hurdle. The import of technology manufacturing industry segments (Cement, Iron
leads to high capital expenditure, something that & Steel and Glass). Although this gives an idea of
many of the depressed industries may not find the possible applications of this technology in India,
feasible. although determining the realisable potential and
acceptability in these industrial sectors requires
4. The high capital cost makes it unattractive for more in-depth sector-wise analysis. Challenges
companies to install these systems. A waste heat faced by the industry related to financing, technology
recovery unit for power generation based on ORC and regulatory issues needs to be identified and
is INR 10 to 13 crores per MW, even more than addressed by involving various stakeholders such
per MW cost of any renewable technology, the as governments, technology providers, and financial
latter being highly incentivised by the government institutions. Different business models (ESCO,
through schemes such as the Feed In Tariffs (FIT), RESCO, captive power plants, third party sale, sale to
Generation Based Incentives (GBI), Accelerated DISCOMs etc.) needs to be explored to bridge the gap
Depriciation (AD) etc. It should be noted that these in the viability of such projects.
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

44
BUREAU OF ENERGY EFFICIENCY

Annexure
Annexure 1: List of waste heat recovery projects used for power generation registered under the clean development

46
mechanism in India

Average Annual
Capacity CDM Status
S. Type of technology Emission
of power of the Company Location Industry Type
No. used reduction (MT CO2
generation Project
per annum)
Rajgangpur,
1 8 MW Approved OCL India Ltd Sundergarh Dist. Sponge Iron Rankine Cycle 32,498
Orissa

Gujarat Alkalis and Alkalis and


2 800 kW Approved Dahej, Gujarat Rankine Cycle 4,631
Chemicals Limited Chemicals

Ghaziabad, Uttar
3 15 MW Approved CCIL Carbon black Rankine Cycle 45,725
Pradesh

M/s Hi-Tech Carbon


Gummidipoondi,Tamil Carbon black
4 25.2 MW Approved (Aditya Birla Nuvo Rankine Cycle 87,305
Nadu manufacturing
Ltd)

Phillips Carbon Carbon black


5 11.30 MW Approved Palej, Gujarat Rankine Cycle 45,721
Black Ltd manufacturing

Tadipatri, Andhra
6 4 MW Approved Ultratech Cement Cement Organic Rankine Cycle 16,871
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Pradesh

Lanco Industries Chittor, Andhra


7 12 MW Approved Cement Rankine Cycle 78,380
Limited Pradesh

Vishnupuram,
8 7.7 MW Approved India Cements Nalagonda, Andhra Cement Rankine Cycle 51,527
Pradesh

Guntur, Andhra
9 2.35 Approved KCP Limited Cement Rankine Cycle 7,766
Pradesh
Average Annual
Capacity CDM Status
S. Type of technology Emission
of power of the Company Location Industry Type
No. used reduction (MT CO2
generation Project
per annum)
Nimbahera,
10 13.2 MW Approved JK Cement Works Chittorgarh, Cement Rankine Cycle 70,796
Rajasthan

Sterlite Industries copper, aluminium


11 11.2 MW Approved Tuticorin, Tamil Nadu Rankine Cycle 18,082
(India) Limited and zinc

Strelite Industries copper, aluminium


12 11.2 MW Approved Tuticorin, Tamil Nadu Rankine Cycle 22,473
India Limited and zinc

Saint-Gobain Glass
13 1.23 MW Approved Tamil Nadu Glass Rankine Cycle 7,854
India ltd (SGGI)

Asahi India Glass


14 1.5 MW Validation Taloja, Maharashtra Glass Rankine Cycle 10,408
Limited

Singhal Enterprises
15 17 MW Approved Gerwani, Chattisgarh Iron Rankine Cycle 1,12,960
Pvt. Ltd

16 17.7 MW Approved Sree Metaliks Ltd. Keonjhar, Orissa Iron Rankine Cycle 1,01,662

Godawari Power &


17 25 MW Approved Raipur, Chattisgarh Iron Rankine Cycle 1,59,926
Ispat Ltd
Hi-tech Power &
18 4.5 MW Approved Raipur, Chattisgarh Iron Rankine Cycle 31,209
Steel limited
Gopani Iron and
Chandrapur,
19 11.5 MW Approved Power (India) Pvt. Iron Rankine Cycle 54,579
Maharashtra
Ltd.
Mahendra Sponge &
20 4 MW Approved Siltara, Chattisgarh Iron Rankine Cycle 19,151

47
Power Pvt. Ltd.
Average Annual
Capacity CDM Status

48
S. Type of technology Emission
of power of the Company Location Industry Type
No. used reduction (MT CO2
generation Project
per annum)
G.R. Sponge and
21 4 MW Approved Raipur, Chattisgarh Iron Rankine Cycle 19,150
Power Ltd
Kamachi Sponge and
22 10 MW Approved Power Corporation Tiruvallur, tamil Nadu Iron Rankine Cycle 42,910
Limited
Vikash Metal &
23 10 MW Approved Puruliya, West Bengal Iron Rankine Cycle 55,131
Power Limited

Sesa Goa Limited &


24 30 MW Approved Bicholim, Goa Iron Rankine Cycle 1,12,357
Videocon Intl Ltd

Action Ispat & Power


25 16 MW Approved Jharsuguda, Orissa Iron Rankine Cycle 88,206
(P) Ltd

Godawari Power &


26 10 MW Approved Raigarh, Chhatisgarh Iron & Steel Rankine Cycle 50,620
Ispat Ltd

Orissa Sponge Iron


27 10 MW Approved Keonjhar, Orissa Iron & Steel Rankine Cycle 41,052
Limited

Godawari Power and


28 7 MW Approved Raipur, Chhattisgarh Iron & Steel Rankine Cycle 17,828
Ispat Ltd (GPIL)
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Shri Bajrang Power


29 18 MW Approved Raipur, Chhattisgarh Iron & Steel Rankine Cycle 1,07,683
& Ispat Limited

Shree Nakoda Ispat


30 6 MW Approved Raipur, Chhattisgarh Iron & Steel Rankine Cycle 32,873
Ltd
Nalwa Sponge Iron
31 16 MW Approved Raigarh, Chhatisgarh Iron & Steel Rankine Cycle 37,825
Limited
Electrotherm India
32 30 MW Rejected Kutch, Gujarat Iron & Steel Rankine Cycle 61,386
Limited

Adhunik Metaliks
33 10.7 MW Rejected Sundargarh, Orissa Iron & Steel Rankine Cycle 80,065
Limited
Average Annual
Capacity CDM Status
S. Type of technology Emission
of power of the Company Location Industry Type
No. used reduction (MT CO2
generation Project
per annum)
Bhushan Power &
34 45 MW Rejected Sambalpur, Orissa Iron & Steel Rankine Cycle 3,33,481
Steel Limited

Ankit Metals &


35 12 MW Rejected Bankura, West Bengal Iron & Steel Rankine Cycle 26,808
Power Limited

Vision Sponge Iron


36 15 MW Withdrawn Puruliya, West Bengal Iron & Steel Rankine Cycle 59,320
Pvt Ltd

Kotmar, Raigarh,
37 16 MW Approved Ind Synergy Limited Iron and Power Rankine Cycle 30,222
Chattisgarh

Rashmi Sponge
38 4.75 MW Approved Raigarh, Chhatisgarh Iron and Steel Rankine Cycle 23,887
Indua Pvt. Ltd

39 25 MW Approved SKS Ispat Limited Raipur, Chattisgarh Iron and Steel Rankine Cycle 1,16,773

Ginigera, Koppal Dist.


40 8 MW Approved Kalyani Steels Ltd Iron manufacturing Rankine Cycle 62,958
Karnataka

Numaligarh Refinery
41 12.075 MW Approved Golaghat, Assam Oil Rankine Cycle 41,885
Limited

SHYAM DRI Power


42 15 MW Approved Sambalpur, Orissa Power Rankine Cycle 94,303
Ltd
M/s Aarti Sponge &
43 4.5 MW Approved Raipur, Chattisgarh Power Rankine Cycle 31,209
Power Ltd

49
Average Annual
Capacity CDM Status

50
S. Type of technology Emission
of power of the Company Location Industry Type
No. used reduction (MT CO2
generation Project
per annum)

44 260 MW Approved JSW Energy Bellary, Karnataka Power Rankine Cycle 12,67,392

Torangallu in
45 100 MW Approved JSW Power Limited Power Rankine Cycle 7,67,325
Karnataka, India

Ranigunj, West Sponge Iron


46 9 MW Approved Jai Balaji Sponge Ltd Rankine Cycle 46,387
Bengal Manufacturing

Sponge Iron
47 4 MW Approved Vandana Global Ltd Raipur, Chhattisgarh Rankine Cycle 18,965
Manufacturing

Sponge iron
48 7.5 MW Approved Tata Sponge Iron Ltd Joda, Orissa Rankine Cycle 31,762
manufacturing

M/s Tata Steel Jamshedpur, Top Pressure Recovery


49 8.1 MW Approved Steel 60,811
Limited Jharkhand Turbine

Jindal Stainless
50 13 MW Approved Duburi, Orissa Steel Rankine Cycle 75,187
Limited

VKG Steel & Energy Kancheepuram, Tamil


51 8 MW Approved Steel Rankine Cycle 36,698
Pvt. Ltd. Nadu
MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA

Ramsarup Lohh Kharagpur, West


52 20 MW Approved Steel Rankine Cycle 1,14,996
Udyog Limited Bengal

53 15 MW Approved Jindal Saw Limited Mundra, Gujarat Steel Rankine Cycle 70,090

MSP Steel & Power


54 16 MW Approved Raigarh, Chhatisgarh Steel Rankine Cycle 59,097
Limited

Jamshedpur,
55 10 MW Approved Usha Martin Limited Steel Rankine Cycle 54,340
Jharkhand
Average Annual
Capacity CDM Status
S. Type of technology Emission
of power of the Company Location Industry Type
No. used reduction (MT CO2
generation Project
per annum)
Electrosteel Midnapore, West
56 12 MW Approved Steel Rankine Cycle 52,330
Castings Limited Bengal

Jindal Steel & Power Village Patrapali,


57 75 MW Approved Steel Rankine Cycle 3,87,643
Ltd (JSPL) Raigarh, Chhattisgarh

Sri Ramrupai
Burdwan District,
58 9.6 MW Approved Balaji Steel Limited Steel Rankine Cycle 51,504
West Bengal
(SRBSL)
Salasar Steel and
59 4.5 MW Approved Raigarh, Chhatisgarh Steel & Power Rankine Cycle 28,358
Power Limited
AML Steel and
60 11 MW Approved Seraikela, Jharkhand Steel & Power Rankine Cycle 57,872
Power Ltd

Monnet Ispat & Kurud Village, Raipur


61 59.5 MW Approved Steel & Power Rankine Cycle 1,18,383
Energy ltd Chhattisgarh

62 5.5 MW Approved Apollo Tyres Limited Vadodara, Gujarat Tyres Rankine Cycle 23,429

Hindustan Zinc
63 9.4 MW Approved Chanderia, Rajasthan Zinc Rankine Cycle 51,609
Limited

51
About
the Indo-German Energy Forum (IGEF)
Background and Objectives
To 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 Projects


The 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.

Federal Ministry Federal Ministry for the Federal Ministry


for Economic Affairs Environment, Nature Conservation, for Economic Cooperation
and Energy Building and Nuclear Safety and Development

Ministry of New and Renewable Energy


Government Of India
BUREAU OF ENERGY EFFICIENCY

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

NEW DELHI BERLIN


Indo-German Energy Forum (IGEF) Indo-German Energy Forum (IGEF)
c/o Deutsche Gesellschaft fr c/o Deutsche Gesellschaft fr
Internationale Zusammenarbeit, (GIZ) GmbH, Internationale Zusammenarbeit, (GIZ) GmbH,
1st Floor, B-5/2, SafdarjungEnclave Kthenerstrae 2,
New Delhi 110 029, India 10963 Berlin, Germany
T +91 11 4949 5353 T +49 30338424 462
M info@energyforum.in M info@energyforum.in
W www.energyforum.in W www.energyforum.in

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