Technical objectives

To design and develop a new generation of ORC for heat recovery adoptable in different EII (Energy Intensive Industries) processes to transfer heat directly from the flue gases to the organic fluid of the ORC system thanks to a Direct Heat Exchange concept, increasing the overall efficiency and reducing costs.

To demonstrate the performance of the whole Waste Heat Recovery (WHR) system, a complete validation in real production conditions is planned in this project by means of a demo installation that will be tested in the CEMENTI ROSSI industrial facility located in Italy.

To develop and validate through a pilot scale test a WHR system to recover and transform the thermal energy of the flue gases of EII into mechanical energy for internal use (compressors).

To develop new heat conductor and anticorrosive materials to be used in parts of the heat exchanger in contact with the flue gases.

To design and model a new integrated control systems for the addressed sectors. To analyse the adaptability/replicability of the developed WHR system to other industrial sectors.

To develop a case study for electricity production exploiting, in a direct heat exchange ORC, the heat contained in the flue gas coming from the petrochemical sludge thermal treatment. This thermal treatment process is made up of the following main stages: pyrolysis/gasification and combustion of the syngas in the second stage.

Economic objectives

To decrease the total investement costs (CAPEX) reducing the complexity of heat xchanges and avoiding intermediate heat carrier circuit up to 10%.

To increase the efficiency of the heat exchangers through technical and design solution and by means of innovative materials/coating up to 15%.

To reduce the total cost per electric output and to increase the efficiency of the system imply to improve investment indicators and to reduce payback period.

Societal and environmental objectives

To increase the Energy Intensive Industry sustainability, reducing their consumption of electric energy, that is a “noble” energy source, implying also reducing primary energy consumption

To avoid CO2 emissions; assuming an average emission factor per power generated in EU, every kWh of electricity generated by a ORC unit in a WHRS avoids 460 kg of CO2.

To become an interesting opportunity of industrial development, since European firms can develop the know how needed for the industrialization of these solution.

To create new job opportunity.