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Communication Feature | July 2017

Waste heat in industrial processes is free profitable green electricity

Peter Lundström, President Sales, Opcon Energy Systems AB, Sweden.

Tell us about your journey in India.
We first came to India and participated in round table discussions arranged by the Swedish Energy Association, Sweden and CII, India in 2013 and 2014, in Hyderabad and Delhi respectively. After meeting many users in India, we realised there was a potential for Opcon products in India. We further felt that to service the market in India, we needed a local representative. In 2014, we finalised an agreement with Ador Green Energy Pvt. Ltd, Mumbai (a member of Ador Group) to market our products in India.

What are the products/solutions you offer specific to the Indian market?
We offer and supply Opcon standalone screw expander power plants (Opcon Powerbox), SRE Flue gas condensers, Saxlund furnaces, and Saxlund material handling equipment. Our initial focus is on establishing Opcon Powerbox in India; the Powerbox uses waste heat available in power, steel, cement and process industries for generating emission free power.

We offer two types of Powerboxes: The Opcon Powerbox-ORC is available for low temperature hot water, steam and other types of heat source; and Opcon Powerbox-WST is available for high pressure dry or wet saturated steam and other types of high pressure gases.

Your strategy is to co-operate with nationally and locally established partners. On what basis is this worked out?
As mentioned above, we have an arrangement with Ador Green Energy Pvt. Ltd, to market our products in India. The arrangement provides for license agreement for manufacturing Powerbox in an Ador factory in Pune, in the future. The objective is to deliver solutions and equipment to the Indian market economically and expeditiously. Depending upon requirements of the end user, decisions would be taken on the type of products to be produced in India.

Kindly elaborate on technology developments for the Opcon Powerbox, which has attracted attention for being eco-friendly.
Opcon Powrbox is a mobile standalone power plant that transforms waste heat, and costs for cooling process hot water, into emission free power. The heart of the technology is in the precision engineered Lysholm turbines developed by Opcon, as well as the advanced screw compressor and screw expander processing equipment. Opcon Powerbox - ORC uses the Organic Rankin Cycle technology in the waste heat recovery plant. Emission free electricity from 100 kW to 1,600 kW can be generated, depending upon availability of waste heat. Since there are no emissions, this would be complete green energy and users would qualify for benefits of green energy certificates. Plants based on ORC technology also qualify for accelerated depreciation, as per the prevailing tax structure.

Waste heat is largely under utilised, much of a market growth do you expect in India?
A market potential study carried out by the Indo-German Energy Forum estimates, the potential for generating electricity with ORC technology would be around 600 MW from waste heat from cement plants across India; likewise, there is potential to generate electricity from waste heat in steel and power plants, as well as float glass and other processing plants.

What is payback period for Opcon Powerbox?
Depending on the characteristics of waste heat available, the payback period is between two to three years.

How does this technology improve performance of gensets and combustion engines?
Opcon Powerbox can reduce fuel combustion by up to 10 per cent, or increase existing power generation by up to 10 per cent, without the need for larger engines or more fuel. It can utilise low grade waste heat such as jacket cooling, scavenge air and exhaust cooling and convert it into cost efficient electricity generation.

What is its role in the off-grid power generation space?
The clean power that is generated in various industries with Powerbox can be used in house as captive power, which is off-grid use of renewable power. In case the power generated is surplus, it can be fed into grid or conveyed to other facilities of the company

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