New technologies to converting heat into usable energy are constantly being developed for renewable use. This means that more interactions between different energy grid will be applied, such as utilizing low thermal waste heat to convert its energy to electricity. With high electricity price, such technology is quite attractive at applications that develop low waste heat. In the case of excess heat in district heating (DH) grid and the electricity price are high, the waste heat can be converted to electricity, which can bring a huge profit for DH companies. Candidate technologies are many and the focus in this degree rapport is on the so-called Organic Rankine Cycle (ORC) that belongs to the steam Rankine cycle. Instead of using water as a working fluid, organic working fluid is being used because of its ability to boil at lower temperature. Because this technique is available, it also needs to be optimized, developed, etc. to achieve the highest appropriate efficiency. This can be done, for example, by modeling different layouts, analyzing functionality, performance and / or do a simulation of various suitable working fluids.  This is the purpose of this degree project and the research parts are to select working fluids suitable at low temperatures (70-120) °C, the difference analysis between the selected fluids and identification of the parameters that most affect the performance. There are many suitable methods to apply to achieve desired results. The method used in this rapport degree is commercial software such as Mini REFPROP, CoolPack, Excel but the most important part is simulation with AspenPlus. The selected and suitable working fluids between the chosen temperature interval are R236ea, R600, R245fa and n-hexane. Three common layouts were investigated, and they are The Basic ORC, ORC with an internal heat exchanger (IHE) and regenerative ORC. The results show that in comparison between 120°C and 70°C as a temperature source and without an internal heat exchanger (IHE), R600 at 70°C, has the highest efficiency about 13.55%. At 110°C n-hexane has the highest efficiency about 18.10%. R236ea has the lowest efficiency 13.16% at 70°C and 16.29% at 110°C. R236ea kept its low efficiency through all results. Without an IHE and a source range from 70 °C up to almost 90 °C, R600 has the highest efficiency and at 90°C n-hexane has the highest efficiency. With an IHE and between (70-90) °C R245fa still has the highest efficiency. With or without IHE and a heat source of 110 °C n-hexane has the highest efficiency 18.10% and 18.40%. R236ea gets the greatest increase 5.2% in efficiency but remains with the lowest efficiency. With Regenerative ORC, n-hexane had an optimal middle pressure about 0.76 bar. The optimal pressure corresponds to a thermal efficiency of 17.52%. The most important identified parameters are the fluid characteristics such as higher critical temperature, temperature source, heat sink, application placement and component performance.         The current simulations have been run at some fixed data input such as isentropic efficiencies, no pressure drops, adiabatic conditions etc. It was therefore expected that the same efficiency curve would repeat itself. This efficiency pattern would differ with less or higher values depending on the layout performance. However, this pattern was up to 90 degrees Celsius and gets a very noticeable change by the change of the efficiency for n-hexane. Therefore n-hexane is chosen with Regenerative ORC because it had the highest efficiency at the highest temperature source tested. This is due definitive to the fluid properties like its high critical temperature compared to the other selected fluids. R236ea remains the worst and that’s also related to the fluid properties. It is also important to note that these efficiencies are only from a thermodynamic perspective and may differ when combining both thermal and economic perspectives as well as application placement. These high efficiencies will certainly be lower at more advanced or real processes due to various factors that affect performance. Factors such as component´s efficiency and selection, pipe type and size, etc. To maintain a constant temperature when it’s not, flow regulation is then necessary and that’s also affects the performance.   The conclusion is that the basic ORC which does not have an IHE and from 70 up to 90 degrees Celsius, R600 has the highest efficiency. Higher temperature gives n-hexane the highest efficiency. With an IHE and between (70-90) °C R254fa has the highest efficiency. At higher temperature source n-hexane has the highest efficiency. ORC with an IHE has the best performance. The R236ea has the worst performance through all results. With regenerative ORC, an optimal meddle-pressure for n-hexane is 0.76 bar. Important parameters are The properties of the fluid, temperature source, heatsink, Application placement and component performance. / Nej

Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2008.

Selecting a suitable power source, during the design process, for a stand-alone soya business unit is challenging and complex. Especially with the aim of optimizing electrical and thermal energy, as well as minimizing the life cycle cost. During the design and development of a soya business unit it was realized that a design tool is needed to assist with the decision making process when selecting a power source. Waste heat can be recovered from either or both the exhaust gas and cooling system of the power source and can be utilized in the soya process. Research of available literature revealed no design tool to assist with the decision making process of the stand-alone business unit and consequently lead to this study. This dissertation presents different possible power sources that could be utilized in supplying energy to the business unit, as well as design tools available. Advantages and disadvantages of the different power sources are discussed. The shortfalls of a number of the available design tools are also discussed. A diesel generator set was selected as the preferred power source for the business unit. Criteria for this selection included the price per kWhe generated, the ease of maintenance, the availability of the diesel generators in rural areas and the availability of diesel as a fuel. The diesel engine was characterized through experimental work for a more in depth understanding of the energy profile of the engine at part load conditions. These results were used as guidelines in the development of the design tool. The design tool was developed with the aim of being user friendly and versatile. The time intervals of the required load of the business unit are flexible. Different types of power sources and fuels can be used within the design tool. User defined heat exchangers are utilized to calculate the possible heat recovery from the power source. The design tool matches the available energy of different power sources at part load conditions with the required load profile of the soya business unit. It then eliminates power sources that would not be able to deliver the minimum required energy. The running cost is calculated for each of the remaining power sources and the power source with the minimum annualized cost, which includes capital cost, maintenance cost and fuel cost, is suggested. The design tool was verified against a base load condition of the soya business unit and the suggested power source showed a saving of 31,4% in electrical energy, an increased overall efficiency of 24,9% and a saving in annualized cost of 27,3%. The design tool can be used to optimize specific components and design options within a combined heat and power system. Sensitivity analysis can be performed with the design tool to determine various influences on the designed system. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2008.

Selecting a suitable power source, during the design process, for a stand-alone soya business unit is challenging and complex. Especially with the aim of optimizing electrical and thermal energy, as well as minimizing the life cycle cost. During the design and development of a soya business unit it was realized that a design tool is needed to assist with the decision making process when selecting a power source. Waste heat can be recovered from either or both the exhaust gas and cooling system of the power source and can be utilized in the soya process. Research of available literature revealed no design tool to assist with the decision making process of the stand-alone business unit and consequently lead to this study. This dissertation presents different possible power sources that could be utilized in supplying energy to the business unit, as well as design tools available. Advantages and disadvantages of the different power sources are discussed. The shortfalls of a number of the available design tools are also discussed. A diesel generator set was selected as the preferred power source for the business unit. Criteria for this selection included the price per kWhe generated, the ease of maintenance, the availability of the diesel generators in rural areas and the availability of diesel as a fuel. The diesel engine was characterized through experimental work for a more in depth understanding of the energy profile of the engine at part load conditions. These results were used as guidelines in the development of the design tool. The design tool was developed with the aim of being user friendly and versatile. The time intervals of the required load of the business unit are flexible. Different types of power sources and fuels can be used within the design tool. User defined heat exchangers are utilized to calculate the possible heat recovery from the power source. The design tool matches the available energy of different power sources at part load conditions with the required load profile of the soya business unit. It then eliminates power sources that would not be able to deliver the minimum required energy. The running cost is calculated for each of the remaining power sources and the power source with the minimum annualized cost, which includes capital cost, maintenance cost and fuel cost, is suggested. The design tool was verified against a base load condition of the soya business unit and the suggested power source showed a saving of 31,4% in electrical energy, an increased overall efficiency of 24,9% and a saving in annualized cost of 27,3%. The design tool can be used to optimize specific components and design options within a combined heat and power system. Sensitivity analysis can be performed with the design tool to determine various influences on the designed system. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2008.

Exploitation of waste heat could achieve economic and environmental benefits, while at the same time increase energy efficiency in process sites. Diverse commercialised technologies exist to recover useful energy from waste heat. In addition, there are multiple on-site and offsite end-uses of recovered energy. The challenge is to find the optimal mix of technologies and end-uses of recovered energy taking into account the quantity and quality of waste heat sources, interactions with interconnected systems and constraints on capital investment. Explicit models for waste heat recovery technologies that are easily embedded within appropriate process synthesis frameworks are proposed in this work. A novel screening tool is also proposed to guide selection of technology options. The screening tool considers the deviation of the actual performance from the ideal performance of technologies, where the actual performance takes into account irreversibilities due to finite temperature heat transfer. Results from applying the screening tool show that better temperature matching between heat sources and technologies reduces the energy quality degradation during the conversion process. A ranking criterion is also proposed to evaluate end-uses of recovered energy. Applying the ranking criterion shows the use to which energy recovered from waste heat is put determines the economics and potential to reduce CO2 emissions when waste heat recovery is integrated in process sites. This thesis also proposes a novel methodological framework based on graphical and optimization techniques to integrate waste heat recovery into existing process sites. The graphical techniques are shown to provide useful insights into the features of a good solution and assess the potential in industrial waste heat prior to detailed design. The optimization model allows systematic selection and combination of waste heat source streams, selection of technology options, technology working fluids, and exploitation of interactions with interconnected systems. The optimization problem is formulated as a Mixed Integer Linear Program, solved using the branch-and-bound algorithm. The objective is to maximize the economic potential considering capital investment, maintenance costs and operating costs of the selected waste heat recovery technologies. The methodology is applied to industrial case studies. Results indicate that combining waste heat recovery options yield additional increases in efficiency, reductions in CO2 emissions and costs. The case study also demonstrates that significant benefits from waste heat utilization can be achieved when interactions with interconnected systems are considered simultaneously. The thesis shows that the methodology has potential to identify, screen, select and combine waste heat recovery options for process sites. Results suggest that recovery of waste heat can improve the energy security of process sites and global energy security through the conservation of fuel and reduction in CO2 emissions and costs. The methodological framework can inform integration of waste heat recovery in the process industries and formulation of public policies on industrial waste heat utilization.