A waste heat recovery system development and analysis using ORC for the energy efficiency improvement in aluminium electrolysis cells

The present work investigates an active waste heat recovery system for the side walls of the aluminium electrolysis cells, enabling utilization of the extracted heat in power generation. This will potentially lead to energy efficiency improvement in the primary aluminium production industry and an enhanced aluminium production rate. An experimentally validated loop thermosyphon heat pipe model was used for heat extraction from the cell side wall. Boosting system thermal efficiency through waste heat recovery, by means of a heat utilization system, and increasing the level of control, as well as thermal equilibrium, stand as the main addressed objectives of the current study, which consequently result in an increased aluminium production rate. An organic Rankine cycle is incorporated into the system, and its performance is evaluated, taking into consideration the operating situations in terms of available temperature and thermal power range.