orc waste heat-holdmann
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ORC Technology for
Waste Heat Applications
Presented at the Diesel Heat Recovery and
Efficiency Workshop December 11, 2007
Gwen Holdmann, Chena Power
Heat Exchanger
GeneratorTurbine
R134a
Refrigerant
Reinjected
Geothermal
Water
Geothermal
Water (from
production well)
Organic Rankine Cycle – Geothermal
UTC Research Center
– Technology
Advancement
Hamilton Sundstrand
Aerospace & Industrial
Pratt & Whitney
Aircraft Engines,
Gas Turbines &
Space Propulsion
Sikorsky
HelicoptersUTC Fuel Cells
On-site &
Transportation
Otis
Elevators,
Escalators &
People Moving
Systems
Carrier
Heating, Cooling
& Refrigeration
UTC Fire & Security
Security &
Fire Protection
UTC divisions span many markets and industries…
United Technologies PureCycle 225
Compressor
Evaporator/Cooler
Condenser
Heat Out
Heat In
Throttle ValveMotor
Power In
Refrigeration Cycle
Centrifugal Chiller
Evaporator/Cooler
CompressorMotor
Condenser
Carrier 19XR2 Centrifugal Compressor
Vapor Compression Cycle (VCC) Organic Rankine Cycle (ORC)
Vapor Generator
Condenser
Heat In
Heat Out
Pump Generator
Power Out
Turbine
Evaporator/Cooler
Condenser
Heat Out
Heat In
Expansion Valve Motor
Power In
Comp
Air
Conditioner
CoolingPureCycle
ORC
Heat
VCC vs. ORC Cycle
Austin Landfill Project
1500ºF Exhaust Gas
Austin Landfill Project
Attached to Candle flare at landfill
Parallel flow evaporator used
Efficiency 9-10%
Max evap temps 350F (mixed in cold air to achieve)
Issues with flame stability
Demonstration ended in 2006
Danville, IL Landfill Recips
900ºF Exhaust Gas
Danville, IL Landfill Recips
2004 startup; 1 year demonstration project
Three 978kW Jenbachers
Required all 3 units to be operating
Exhaust temps 900+F
Chena Geothermal Power Plant
Based on ORC Technology
400 kW net; installed in 2006
Uses 800 gpm of ~164ºF water
Air and water cooled
Reduced local cost of power from 30¢ to 5¢
Total project cost $2.2 million
Projected savings $500,000 in 2007
Simple Payback 4 years
Provides additional revenue opportunities
Chena Geothermal Power Plant
0
20
40
60
80
100
120
140
160
180
0:00:00 4:48:00 9:36:00 14:24:00 19:12:00 0:00:00
OIL_TSAT (°F)
EVAPTSAT (°F)
OILT (°F)
WINDT (°F)
LIQLINET (°F)
CONDEWT (°F)
EVAPEWT (°F)
EVAPLWT (°F)
CONDLWT (°F)
0
50
100
150
200
250
0:00:00 4:48:00 9:36:00 14:24:00 19:12:00 0:00:00
OILSUMPP (psia)
OILP (psia)
EVAP_P (psia)
PUMPEXP (psia)
COND_P (psia)
Temperatures
Pressures
Extremely stable operation:
• Cold temp affects gross power.
• Hot temp doesn’t vary.
• 99.4% availability
8/23/07
Averaged values – 8/23/07
CondEWT (F) 41.64
CondLWT (F) 49.88
EvapEWT (F) 162.97
EvapLWT (F) 131.88
EvapP (psia) 217.45
CondP (psia) 62.80
PumpKW (kW) 20.36
GenKW (kW) 196.09
RefFlow (#/s) 23.22
TsatEvap (F) 131.40
TsatCond (F) 52.30
EvapGPM (gpm) 488.55
CondGPM (gpm) 1666.98
Typical Operating Conditions at Chena
0
50
100
150
200
250
12/23/20
06 18:28
12/23/20
06 18:43
12/23/20
06 18:57
12/23/20
06 19:12
12/23/20
06 19:26
12/23/20
06 19:40
RunState
OilSumpP
OilTsat
EvapExitP
OIL TSAT over 110 deg
(inadvertent closure of 10 inch valve)
Alarm 26 High low side pressure
(High Oil Tsat) Condenser fans on
Manual Control
Atypical Operating Conditions at Chena
Added load of 24kW
when fans are running
Air Cooled Condenser
CONDENSER
ELECTRONICS
TURBINE
EVAPORATOR
3.2m MAX
(10’- 4”)
ESTIMATED DRY
WEIGHT = 10,000 kg(22,000 LBS)
5.1m
(16’- 10”)2.1m
(7’- 5”)
UTC PureCycle 225 Product
Raser Technologies Project
O&M Costs
UTC provides a service contract (optional, in addition to
standard 1 year warranty)
$22,000 per year with 3% escalator for 5 years
Based on Carrier Chiller maintenance contracts
Equates to 1.3 cents per kWhr produced in first year, 1.5
cents per kWhr in year 5
Includes routine maintenance and inspection of
components, condenser cleaning, plus unscheduled
maintenance
Does not include parts and labor for 40,000 hour turbine
overhaul (end of 5 years) or additional oil or refrigerant
Seneca Meadows, NY Project
Large Greenhouse Facility
20MW Diesel Recips used
to supply power to site
Jacket water used for
facility
Stack heat recovery
Plan to install multiple
ORC units
2.5 MW Diesel Genset
2.5 MW Electricity
2.5 MWth
rejected to
Jacket Water
2.5 MWth
rejected to
exhaust
Assume 10% efficiency for ORC’s
Can generate 400kW off stack heat and jacket water
Increase power output by 14%
Potential Savings of over 250,000 gallons of fuel
Minimum Recip Size Requirements
Exhaust Heat Recovery
Example: Fish Processing Facility
Example: Fish Processing Facility
ANNUAL SAVINGS
225 kW (90% capacity factor)
1872.45 MWhrs per year
13 kW/ga diesel fuel
17 gallons offset per hour
144,035 gallons offset per year at 95% availability
$360,087 Savings based on $2.50 diesel fuel
$30,007 Savings per month
BUDGET
310,000 Power Plant
12,500 Shipping (25,000 lbs) 8ftx20ftx10.5ft
50,000 Maintenance Contract
100,000 Design and Installation of Unit
10,000 Permitting
100,000 Cooling System
582,500 TOTAL
19.4 PAYBACK (months)
ORC Oil and Gas Project
PH Cycle Diagram for Chena Design
0
50
100
150
200
250
300
350
400
60 100 140 180
Enthalpy (Btu/lbm)
Pre
ssu
re (
lbf/in
2)
TS Cycle Diagram for Chena Design
0.0
50.0
100.0
150.0
200.0
250.0
0.20 0.25 0.30 0.35 0.40 0.45
Entropy (Btu/(lbm-R))
Te
mp
era
ture
(F
)
0
50
100
150
200
250
300
350
400
0 50 100 150 200 250 300 350
Saturation Temp (F)
Pre
ssu
re (
psia
)
Max working Pressure
R134a
R245fa
Maximum
boiling temp.
r245fa and
r134a.
• Previous ORC units produced by
UTC used r245fa
• Using low-temperature
geothermal at 165 F required a
switch to r134a
• Also requires lower cold source
temperature (Chena has cold
stream water available year-
round)
Chena Geothermal Power Plant
Wellon
Hot Oil
Evap2.12 MW
Pump48 kW
Turb291 kW
Cond1.872 MW
Recup.
Evap1.87 MW
Pump27 kW
Turb225 kW
Cond1.62 MW
D. Heating
Radiator
118 psia,
536 F
8.4 psia,
484 F8.4 psia,
332F
8.4 psia,
302F
118 psia,
307 F
118 psia,
441 F
600 F
450 F
220 F290 F
25 psia,
135 F
300 psia,
85 F, 16.3#/s
25 psia,
83 F
80 F
60 F
290 F300 psia,
256 F
240 kW net
12.0%
XBiomass Configuration
243 kW net
11.5%
Future Plans
1MW unit will be available in mid-2009
Titanium tube condenser mid-2008
Air cooled condenser (product) available in mid-2009
CHENA HOT SPRINGS RESORT
www.chenahotsprings.com
Mile 56 Chena Hot Springs Rd, Fairbanks, AK
(907) 451-8104
Gwen Holdmann
VP, New Development
gwen@yourownpower.com
www.yourownpower.com
(907) 451-8104
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