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ENERGY BUSINESS
UNIT (EBU)

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A. WASTE HEAT TO ELECTRICAL GENERATOR (WHEG) OR LOW GRADE HEAT TO ZERO COST
ELECTRICITY GENERATORS.

• Assure® WHEG is a stand--alone

alone power plant that transforms waste heat into emission free power
production and new revenues. Solid industrial components and easy installation, together with
microprocessor controls, and remote operation result in high operational reliability.
• Climate change and the emerging need to reduce CO2 and other emissions, call for increased
environmental concern on a national and global level.
• Assure® WHEG contributes towards meeting their end-user’s
end user’s environmental and energy efficiency
commitments, while improving system performance and profitability at the same time.
• By utilizing waste and residual heat, new power production is both fuel and emission free. This makes
Assure® WHEG eligible for green certificates, feed-in
in tariffs, energy efficiency commitments and emission
trading.

The WHEG is based on the basic principle of Organic Rankine Cycle(ORC).An

An ORC module is a thermodynamic
machine that transforms waste heat into electricity through a turbine fed by an organic fluid circulating in a low-
low
pressure closed circuit.

Proven for decades, the ORC technology requires very little maintenance and is particularly adapted to various heat
sources at low and medium temperatures (Above 80’C) within small and medium size production sites.

The generation of electricity from thermal sources at low temperatures (below 300°C)
300°C) is possible thanks to organic
fluids (refrigerants).

The main property of these fluids is that they evaporate at a low temperature. This allows efficient use of heat in low
power applications (from an order of a few kW to several MW). The thermodynamic cycle using these refrigerants is
named after its inventor, William J. M. Rankine.

The Technology

The ORC operates similar to the steam Rankine cycle, but uses an organic working fluid instead of water,which
water have
a lower boiling point and higher vapor pressure than water. This allows the Rankine cycle to operate with significantly
lower waste heat temperatures - sometimes as low as 66°
66°C.
C. The most appropriate temperature range for ORCs will
depend on the fluid used, as fluids' thermodynamic properties will influence the efficiency of the cycle at various
temperatures.

In comparison with water vapor, the fluids used

used in ORCs have a higher molecular mass, enabling compact designs,
higher mass flow, and higher turbine efficiencies (as high as 80–85%).
80 85%). However, since the cycle functions at lower
temperatures, the overall efficiency is only around 10–20%,
10 depending on the temperature of the condenser and
evaporator. While this efficiency is much lower than a high
high-temperature
temperature steam power plant (30-40%),
(30 it is important to
remember that low-temperature
temperature cycles are inherently less efficient than high-temperature
high temperature cycles.

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ORC
C technology is not particularly new; at least 30 commercial plants worldwide were employing the cycle before
1984. Its applications include power generation from solar, geothermal, and waste heat sources. Waste heat recovery
can be applied to a variety of low-to
to medium-temperature
medium temperature heat streams. Although the economics of ORC heat
recovery need to be carefully analyzed for any given application, it will be a particularly useful option in industries that
have no in house use for additional process heat or no neighboring plants that could make economic use of the heat.

MARKET

The market that Assure® WHEG targets is the sub 500 kilowatt market because there are no serious competing
products in that space and plenty of demand. The heat energy which fuels the ORC comes from myriad sources;
geothermal, biomass, industrial, hot exhausts, ovens, furnaces, flue gas condensation, fermentation,

compressors, power cycle compressors, concentrated solar thermal power etc. The family of Assure® WHEG can
adapt to generation below 500kW, an underserved market area. The company’s Assure® WHEG products are
correspondingly at the high end of the quality scale. Customers value electrical reliability, off grid or offsetting grid
costs by its mobile installation capability, small footprint
fo and efficiency.

CARBON REDUCTION PROGRAMS.

There is a big push around the world to reduce carbon emission levels and offset further carbon emission from
such things as coal power stations and by industry making efficiency improvements across a range
ran of areas.
Where there is a source of wasted heat, by installing Assure®WHEG
Assure® equipment all users put significant and
immediate Carbon Reduction into their sustainability programs.

BENEFITS

Inside the fence installation on existing sites.

No Additional Fuel Consumption

No Water Consumption with closed loop

Increased Plant / process efficiencies. operation.

Fuel Savings.
No Creation or disposal of Waste.

Short Payback Period.
Displaces fossil fuel based energy.

Low Maintenance
No New Transmission Line.

20 year Life Expectancy
Companies are willing to use waste heat due
to •increasing energy costs and

CO2 –Free
Free Additional Power

Emission trading.
APPLICATIONS

Sample Waste Heat
Power Plant Exhaust Exhaust

Applications
Combustion Turbine
Micro Turbine Exhaust

Cogen exhaust heat to Exhaust
Fuel Cell Exhaust
power
Reciprocating Engine
Large Boiler Stack

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Exhaust
Factory Ships
Brick Ovens

Cement Processing
Container Ships
Renewable

Ore Processing
Cruise Ships
Geothermal

Petrochemicals
Industrial Processes
Solar Thermal

CHP Engine Waste
Glass Plants
Ocean Thermal
Heat Recovery
Thermal Oxidizers
Food Processing

Heat recovery from
Paint Ovens
Beverage Bottling
steam condenser
Ovens
Wineries

Waste Steam
Air Compressors
Chip Lines

Grey Water
Gas Compressors
Bakeries

Ocean Shipping
Fry Lines
Breweries

Factors Affecting Feasibility

Evaluating the feasibility of waste heat recovery requires characterizing the waste heat source and the stream to
which the heat will be transferred. Important waste stream parameters that must be determined include:

• Heat quantity. A large and constant volume of heat is ideal, although there are options for smaller heat quantities.
• Heat temperature/quality. A high-temperature
temperature heat source can yield greater outputs, although the temperatures can
also affect what materials are used in the equipment design of heat exchangers and recovery systems.
• Composition.. A heat source free of corrosives or particulates is best; otherwise, more expensive heat exchangers
and maintenance increase the costs.
• Minimum allowed temperature.. Too cool a temperature can ca
cause
use the water vapor in exhaust gas to condense and
deposit corrosive substances on the heat exchanger.
• Operating schedules, availability, and other logistics
logistics.. For example, it is important that the schedule of the heat
source match the schedule of the heat load. It is also important that the recovery not interfere with the industrial
process that is the source of the waste heat.
• Location. When generating electricity, a close proximity to the electric grid (and ideally a transmission line) is
preferable.
• Economic incentives.. Some states offer tax credits, grants, and/or eligibility in renewable portfolio standards, any of
which help the economic feasibility.

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Temperature Commercial Waste Heat to

Waste Heat Source Characteristics
Classification Power Technologies
Furnaces Steel electric arc
· Steel heating
· Basic oxygen
· Aluminum reverberatory High quality heat
· Copper reverberatory High heat transfer
· Nickel refining High power-generation
generation
Waste heat boilers and
High (>650'C) efficiencies
· Copper refining steam turbines
Chemical and
· Glass melting mechanical
· Iron cupolas contaminants
· Coke ovens
· Fume incinerators
· Hydrogen plants
Prime mover exhaust streams
· Gas turbine
Medium power-
· Reciprocating engine
generation efficiencies. •Waste heat boilers and
· Heat
Heat-treating furnaces Chemical and steam turbines (>260'C) •
Medium (260'C –
· Ovens mechanical Organic Rankine cycle
650'C)
· Drying contaminants (some (<425'C) • Kalina cycle
streams such as cement (<538'C)
· Baking
kilns)
· Curing
· Cement kilns
· Boilers
· Ethylene furnaces
· Steam condensate Energy contained in
numerous small sources
· Cooling Water
Low power-generation
generation
· Furnace doors •Organic Rankine cycle
Efficiencies
(>150'C gaseous streams,
Low (< 260'C) · Annealing furnaces Recovery of combustion
>80'C liquid streams)•
· Air compressors streams limited due to
Kalina cycle (>95'C)
acid concentration if
· IC engines
temperatures reduced
· Refrigeration condensers below 120'C
· Low-
Low-temperature ovens
· Hot process liquids or solids

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BASIC PRODUCT DIMENSIONS

Performances (Electricity Generation /

Units 10KWe 20KWe 30KWe
Heat Supplied
Electricity Power up to KW 5 10 15 20 25 30
Cogeneration efficiency 95% 95% 95% 95% 95% 95%
Thermal Power KW 45 80 156 170 260 255
Inlet Temperature C 20-30 20-30 20-30 20-30 20-30 20-30
Outlet Temperature C 30-40 30-40 30-40 30-40 30-40 30-40
Thermal power required (Heat Required)
Thermal power KW 53 95 180 200 300 300
Inlet Temperature C 125-135 140-150 125-135 140-150 125-135 140-150
Outlet Temperature C 105-115 115-130 105-115 115-130 105-115 115-130
Installation (Dimensions)
Electrical Connections (Three-Phase)
Phase) 400V/50Hz,32A 400V/50Hz,100A 400V/50Hz,100A
Weight Kg 600 1150 1300
Dimensions 1700x1500x750 2000x1900x1040 2000x1900x1040
Flanges Heat Required PN40 / DN 40 PN40/DN50 PN40/DN50
Flanges Heat Supplied PN16/DN32 PN16/DN40 PN16/Dn40

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COSTING+SAVINGS+REVENUES+CARBON CREDITS

Savings or Savings or Savings or Kg of Ton of

Assure®
Estimated Revenue Revenue Revenue Carbon/hr Carbon/year Carbon
Solution Capacity Kg of
Investment PER per year per year per year based on based on Credit/year
Model (Kwe/hr) Carbon/year
Skid (INR) usage at Rs usage at Rs usage at Rs 2000kwe per 2000kwe in INR
(WHEG)
3/Kwe 5/Kwe 6/Kwe ton per ton

AS05 5
500,000.00
131,400
219,000
262,800 3.48 30,493.56 30.5
19,821

AS10 10
1,000,000.00
262,800
438,000
525,600 6.96 60,987.12 61.0
39,642

AS20 20
2,000,000.00
525,600
876,000
1,051,200 13.92 121,974.24 122.0
79,283

AS30 30
3,000,000.00
788,400
1,314,000
1,576,800 20.89 182,961.36 183.0
118,925

AS50 50
5,000,000.00
1,314,000
2,190,000
2,628,000 34.81 304,935.60 304.9
198,208

AS80 80
8,000,000.00
2,102,400
3,504,000
4,204,800 55.70 487,896.96 487.9
317,133

AS100 100
10,000,000.00
2,628,000
4,380,000
5,256,000 69.62 609,871.20 609.9
396,416

AS125 125
12,500,000.00
3,285,000
5,475,000
6,570,000 87.03 762,339.00 762.3
495,520

AS150 150
15,000,000.00
3,942,000
6,570,000
7,884,000 104.43 914,806.80 914.8
594,624

AS200 200
20,000,000.00
5,256,000
8,760,000
10,512,000 139.24 1,219,742.40 1,219.7
792,833

AS250 250
25,000,000.00
6,570,000
10,950,000
13,140,000 174.05 1,524,678.00 1,524.7
991,041

AS300 300
30,000,000.00
7,884,000
13,140,000
15,768,000 208.86 1,829,613.60 1,829.6
1,189,249

AS350 350
35,000,000.00
9,198,000
15,330,000
18,396,000 243.67 2,134,549.20 2,134.5
1,387,457

AS400 400
40,000,000.00
10,512,000
17,520,000
21,024,000 278.48 2,439,484.80 2,439.5
1,585,665

AS450 450
45,000,000.00
11,826,000
19,710,000
23,652,000 313.29 2,744,420.40 2,744.4
1,783,873

AS500 500
50,000,000.00
13,140,000
21,900,000
26,280,000 348.10 3,049,356.00 3,049.4
1,982,081

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