In recent years energy debates and emission regulations have pushed the whole world to explore alternative forms of energy, therefore it is important to explore innovative Measures to overcome the challenges of future fuel gas production shortage, future electric demand increase and GHG emission reduction. Industrial waste heat refers to energy that is generated in industrial process without being used, Waste heat recovery entails capturing and reusing the waste heat.

This paper introduces a case study to utilize the new ORC technology (Organic Rankine Cycle technology) on an existing El Gamil gas treatment plant, in order to recover the waste heat produced from no.4 turbo compressors exhaust with the aim of using it for process heating and power generation. A simulation model has been built up for two different types of engineering cycle, Different types of working fluids have been investigated for each cycle through different technical parameters in order to choose the best cycle and working fluid.

The simulation model shows that the regenerative cycle and cyclo-pentane as a working fluid is the most suitable selection for recovering the waste heat and convert it to process heating and power generation. The selected solution shows that the maximum power generated is 36 MW, the maximum cycle efficiency is 27% and the lowest working fluid volumetric flow rate is 7000 ACMH. On the other hand the economic study shows that the ORC technology is feasible, where the payback period is 4.5 year and IRR is 29%. The ORC technology saved fuel gas by 5,000,000 MMBTU/year, which environmentally decrease the CO2 emissions by 300,000 ton/year. And this enhances confidence towards applying the ORC technology in such gas treatment plants.

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