Energy efficiency enhancement of a thermal power plant by novel heat integration of Internal Combustion Engine, Boiler, and Organic Rankine Cycle

Abstract

AbstractThe utilization of waste energy contributes to reducing carbon emissions and mitigating global warming. A novel heat integration system comprising an Internal Combustion Engine (ICE), Boiler, and Organic Rankine Cycle (ORC) coupling is techno‐economically examined in this study. The feasibility of waste heat recovery from industrial boilers of a thermal power plant (Gadoon Textile Mills Limited, Pakistan) having 2.66‐MW capacity was assessed. This was done by efficiently harnessing the waste heat from boiler exhaust gas by coupling an existing system with an ORC. A steady‐state simulation model of the ICE‐Boiler‐ORC system was developed through Power Plant Simulator and Designer (PPSD) software to perform a multiparametric study. Additional heat power (3710 kW) was extracted from the boilers' waste gases through ORC. Consequently, the overall plant thermal efficiency was enhanced from 61.84% to 82.68% and the overall net electric efficiency of the existing system was increased by 0.9%. The average payback period was found 4.2 years based on different plant operation scenarios and equipment prices (Chinese or European origin). Therefore, the proposed system holds significant technical and economic potential for enhancing energy efficiency through low‐grade waste heat and proves to be economically viable with a short payback period.