Organic Rankine Cycle (ORC)

Waste Heat Generator (WHG)

Technical Information provided
by Greenvironment plc
confidential
1
Waste Heat Generator (WHG)
Converts waste heat into electricity
Capable of using low grade waste heat
Waste Heat Generator (WHG)
2
Turbines
Devices that converts fluid
flow into work
Gas turbine
Working fluid is combustion
products and air
Water turbine (hydro)
Working fluid is water
Steam turbine
Rankine Cycle water is boiled
to vapor before passing through
turbine
Working fluid is water vapor
(steam)
3
Rankine Cycle
Thermodynamic cycle which converts
heat into work
Working fluid is often steam
Requires high temperatures to vaporize water
80% of all power in the world is produced with this
technology
Water
CONDENSER
Low Temperature
heat sources produce
little useable steam
Inherit problem is
high latent heat of
water in liquid-vapor
phase change
4
Organic Rankine Cycle
For many (low temperature) waste heat applications, we
need a fluid that boils at a lower temperature than water
Historically, such fluids have been hydrocarbons - hence
the name Organic
Modern Working Fluids include: Propane / Pentane /
Toluene / HFC-R245fa
These Working Fluids allow use of Lower-Temperature
Heat Sources because the liquid-vapor phase change, or
boiling point, occurs at a lower temperature than the water-
steam phase change
Water R245fa
1 bar (0 psig) 100C (212F) 15,6C (60F)
19,6 bar (270 psig) 212C (413F) 121C (250F)
5
Waste Heat Sources
Waste heat is any source of otherwise unused
heat that is why fuel is free
Waste heat from MicroTurbine exhaust
Waste heat from industrial processes
Process stacks from drying or heating processes
Heat from waste fuel
Biomass or Biogas is burns to produce heat directly
Not waste heat
A boiler creates heat for vaporization in a closed loop
system not free fuel
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The Complete System
Integrated
Power
Module
Evaporative
Condenser
Evaporator
Heat
Source
375F (190C)
3 MBTU/H
Generate
125 kW
R245fa
Pump
7
How it Works - 1
Integrated
Power
Module
Evaporativ
e Condenser
Receiver
Economizer
Evaporator
Liquid
85F (29C)
230psig
(16bar)
Heat Source
375F (190C)
3 MBTU/H
Generate
125 kW
Liquid
85F (29C)
26psig
(1.8bar)
R245fa
Pump
The working fluid is in the receiver as a liquid at the condensing pressure and temperature. It
enters the pump where the working fluids pressure is raised to the evaporating pressure.
8
How it Works - 2
Evaporative
Condenser
Receiver
Economizer
Evaporator
Heat Source
375F (190C)
3 MBTU/H
Liquid
118F
(48C)
220psig
(15bar)
R245fa
Pump
The working fluid passes through a heat exchanger (Economizer) to take heat out of the gas
leaving the Integrated Power Module. This improves system efficiency. The working fluid is now
a warmer, high pressure liquid.
Integrated
Power
Module
Generate
125 kW
Liquid
85F (29C)
230psig
(16bar)
Liquid
85F (29C)
26psig
(1.8bar)
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How it Works - 3
9
Evaporative
Condenser
Receiver
Economizer
Evaporator
Vapor
240F
(115C)
220psig
(15bar)
Heat
Source
375F
(190C)
3 MBTU/H
R245fa
Pump
The working fluid enters the Evaporator, where the working fluid is exposed to waste heat which
evaporates the fluid to a high pressure vapor.
Integrated
Power
Module
Generate
125 kW
Liquid
118F
(48C)
220psig
(15bar)
Liquid
85F (29C)
230psig
(16bar)
Liquid
85F (29C)
26psig
(1.8bar)
Integrated
Power
Module
10
How it Works - 4
Evaporative
Condenser
Receiver
Economizer
Evaporator
Heat Source
375F (190C)
3 MBTU/H
Vapor
145F
(63C)
26psig
(1.8bar)
R245fa
Pump
The working fluid (now a vapor) enters the turbine of the IPM. The working fluids pressure drops
across the turbine to the condensing pressure, spinning the turbine (which is connected to the
generator) in the process. The driving force is the pressure difference across the turbine.
Generate
125 kW
Vapor
240F
(115C)
220psig
(15bar)
Liquid
118F
(48C)
220psig
(15bar)
Liquid
85F (29C)
230psig
(16bar)
Liquid
85F (29C)
26psig
(1.8bar)
11
How it Works - 5
1
1
Evaporative
Condenser
Receiver
Economizer
Evaporator
Heat Source
375F (190C)
3 MBTU/H
R245fa
Vapor
85F
(29C)
26psig
(1.8bar)
Pump
The working fluid still has an enormous amount of heat, some of which is transferred to the
pumped liquid in the economizer. This helps in two ways: 1) this heat would have otherwise
been extracted in the condenser and; 2) there is less heat required at the evaporator due to the
liquid being pre-warmed.
Vapor
145F
(63C)
26psig
(1.8bar)
Vapor
240F
(115C)
220psig
(15bar)
Liquid
118F
(48C)
220psig
(15bar)
Liquid
85F (29C)
230psig
(16bar)
Liquid
85F (29C)
26psig
(1.8bar)
12
How it Works - 6
Evaporative
Condenser
Receiver
Economizer
Evaporator
Heat
Source
375F
(190C)
3 MBTU/H
Ambient
Air 75F
(24C)
Wet Bulb
R245fa
Vapor
85F (29C)
26psig
(1.8bar)
Pump
The working fluid (still a vapor) then flows to the condenser where heat is extracted and the
working fluid condenses to a liquid.
Vapor
85F
(29C)
26psig
(1.8bar)
Vapor
145F
(63C)
26psig
(1.8bar)
Vapor
240F
(115C)
220psig
(15bar)
Liquid
118F
(48C)
220psig
(15bar)
Liquid
85F (29C)
230psig
(16bar)
Liquid
85F (29C)
26psig
(1.8bar)
13
How it Works - 7
Evaporative
Condenser
Receiver
Economizer
Evaporator
R245fa
Pump
The low pressure, liquid working fluid drains back to the receiver and is ready to be pumped to
high pressure and flow towards the integrated power module.
Heat Source
375F (190C)
3 MBTU/H
Ambient
Air 75F
(24C)
Wet Bulb
Vapor
85F (29C)
26psig
(1.8bar)
Vapor
85F
(29C)
26psig
(1.8bar)
Vapor
145F
(63C)
26psig
(1.8bar)
Vapor
240F
(115C)
220psig
(15bar)
Liquid
118F
(48C)
220psig
(15bar)
Liquid
85F (29C)
230psig
(16bar)
Liquid
85F (29C)
26psig
(1.8bar)
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Applications
Turbines Exhaust
Waste heat from exhaust
Industrial Stack Gas
Refineries
Incinerators
Drying processes
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Applications
Geothermal
Water or Steam
Solar Thermal
After steam process
Indirect evap source
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The ORC Power Skid
Capstone supplies the ORC Power Skid
Includes electronics, receiver, economizer, power module and
various pumps
Needs external evaporator and condenser
Power Skid Fluid Connections
Warm Liquid to
Evaporator
Cool Liquid from
Condenser
Hot Vapor from
Evaporator
Warm Vapor to
Condenser
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Power Skid Components
Receiver
Pump
Field
Connections
Integrated
Power
Module
Power
Electronics
Programmable
Logic Controller
(PLC) & Magnetic
Bearing Controller
(MBC)
VFD for Pump
Separator
Inlet Control
Valve
Bypass
Valve Economizer
Separator
Drain Valve
Slam
Valve
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Power Skid Specs
Turbine Expander and Generator
Hermetically sealed power module no leaks
Magnetic Bearings no lubricants
26,500 rpm no vibration
Power electronics 125 kW
Grid Connect only
380-480V, 3 phase, 3 wire 50/60 Hz
Working fluid HFC-R245fa
Dry weight 7,000 lbs
46 w x 112 l x 79.5 h
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Evaporator
Transfers waste heat energy to refrigerant,
resulting in vaporization
Direct, heat transfers directly from the waste heat source
to the working fluid
Likely choice for a Microturbine application where waste
temperatures are low and exhaust stream is clean
Heat source needs to be near ORC
Indirect, thermal transfer medium is used between the
heat source and the working fluid (e.g. thermal oil, hot
water, steam)
Requires more ancillary equipment
Less efficient overall
Good fit if heat source is far from ORC
21
Condenser
Rejects latent heat of working fluid, resulting in
condensation
Direct The working fluid passes through a heat
exchanger that rejects heat directly to the environment.
Indirect A medium such as water is passed through a
heat exchanger and takes the rejected heat out of the
working fluid. The medium then transfers the heat
somewhere else.
Cooling towers, air cooled condenser (Dry Cooler),
ground water, evaporative condenser
Cooling towers (if already existing) and direct evaporative
condensers are likely the best match for MicroTurbine
applications
22
Installation Considerations
Evaporator & Condenser must be within 50ft of the
ORC power skid
Minimize refrigerant run length
Minimize heat loss / absorption
Minimize amount of R245fa used
Condenser must be elevated (flow to receiver)
Qualified technician required to handle R245fa
Internal cleanliness (of R245fa loop) important
23
Complete Installation
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Heating, Cooling, Power
Cycle effectiveness is determined by the
heat source and condensing source
Determine total heat and temperature available
Determine total cooling available
Power available is determined by multiplying
the heat available by the cycle effectiveness
More heat available => less cooling required
Less heat available => more cooling required
25
Available Power Output
More heat is
required for a
given power
production as
condensing
temp increases.
Size heat
source and
condenser for
ambient
conditions.
26
ORC with MicroTurbines
Typical MicroTurbine implementation
6 to 8 Capstone C65 MicroTurbines
One ORC WHG Power Skid
One direct MT exhaust to refrigerant heat
exchanger
One direct evaporative cooling tower or
piggyback on existing cooling tower.
27
Free Electricity?
Or, how to build a ORC WHG value
proposition
System uses low grade heat that is usually
wasted no other good use
Increase overall efficiency of systems
Consumes no additional fuel
Produces no additional emissions
Wasted energy into electric power may
Reduce demand charges
Capture carbon credits
Qualify for renewable energy incentives
28
Calculating New Efficiency
Using waste heat to generate electric power
increases overall system efficiency
Low grade waste heat is used, so assume it can
not be used for any other purpose
Example, 6 Capstone C65s
Produce 390kW at 29% Electric Eff
A 125kW ORC WHG is added
515kW is produced, using no added fuel
new efficiency is
(New power/old power)*old Efficiency = 38%
The ORC increases electric efficiency to over 38%
29
Case Study
Biomass boiler test site in the south east USA.
30
Case Study Payback
Free fuel and low Maintenance Cost provide
payback
Annual Run Hours 8,400
Net Electrical Output 107kWe
Annual Production 8,400 x 107 = 898,800 kWh
Gross Revenue 898,800 x $0.18 = $161,784
Maintenance Cost 898,800 x $0.0075 = $6,741
Net Annual Revenue $155,043
Cost of Project $298,000
Simple Payback < 2 years
31
Technology Advantages
Very similar to those of Capstone MicroTurbines
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