dipti dash, kay kwok & fabio sventurati, ge

© 2013, General Electric Company.

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Dipti Dash

GE Power & Water

Dipti Dash, Kay Kwok & Fabio

Sventurati

Presented at: Texas Combined Heat and Power and Waste Heat to Power Annual Conference & Trade Show October 7-8, 2013 Houston, Texas, USA

Industrial Waste Heat to Power Solutions




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GE Power & Water

Objective Part 1: Industrial Waste Heat to Power Segments

Part 2: GE ORC Technology - Clean CycleTM

Part 3: GE ORC Technology - ORegen TM

Part 4: Super Critical CO2 Technology



Industrial Waste Heat to Power (WHP) Segments

Part 1:



Dipti Dash

5



Green, CO2 free technology

Engines & Gas Turbines Geothermal

Conventional

GE Technology

New Technology ... Heat Recovery Program Focus

100°C 200°C 400°C 500°C 600°C

Conventional Steam Cycles

Advanced Heat Recovery Technologies

300°C

Industrial Large GT Solar

WHP market segments

http://www.trec-uk.org.uk/images/schott_parabolic_trough.jpg

6



ORC (O&G)

ORegenTM

Steam (P&W)

Industrial GT Exhaust

Fu

el F

ree P

ow

er

(MW

)

10

20

30

40

50

200 100

Waste Heat Temp. (Deg C)

300 400 500 600

ORC (P&W)

Clean Cycle

700

Steam (P&W)

Aero GT Exhaust

Up to 180

MW

Steel Mill

Cement Refinery

Geothermal

Broad applications with wide temperature range

GE WHP technology solutions

ORegen Growth

Potential

ORC – Organic Rankine Cycle

O&G – GE Oil & Gas division

P&W – GE Power & Water division

The Clean Cycle

Heat to Power Generator

Part 2:



Kay Kwok

8



Clean Cycle heat to power generators

Heat source

• Heat energy is captured from

exhaust streams

• Requires >800kWth at

>300°F

• Example: 1.5MW recip

engine

HEAT POWER

Recip

engines

Biomass

boilers

Turbines

Clean Cycle generator

• One unit generates ~100kW

• Modular, re-deployable

• More heat? Stack multiple

units

• No fuel, no emissions

Electricity

• Distributed, base-load;

90%CF

• Power factor of 1 matches

grid

• Sold to grid for revenue, or

used on-site

9



Why heat to power

Industrial Efficiency

“20 to 50% of industrial energy input is lost as waste

heat.”1

“The U.S. industrial sector accounts for about 1/3 of the

total energy consumed in the United States” 1

Power plant efficiency

“The global average efficiency of power plants that

generate only electricity is 41%. Almost 3/5 of the primary

energy used in these plants becomes waste heat, of no

economic value.”2

Why Organic Rankine Cycle?

“About 60% of waste heat losses are at temperatures

below 450°F [230°C].” 1

Sources: 1 2008 DOE report: “Waste Heat Recovery: Technology and Opportunities in US

industry” 2 International Energy Agency, World Energy Outlook 2012

10



Clean Cycle II

power

IPM

cooling

156°F

95°F

277°F

98°F

How the Clean Cycle works • Closed circuit hot water loop delivers heat energy and allows access to a wide range of heat temps

• Cooling is typically achieved by a water or air cooled condenser

• Power produced is grid quality due to built in power electronics and inverter

Water loop

~300°F

Exhaust heat

>300°F

11



Benefits of 100kW of fuel free power

Assumptions: 100kW at 8,000 operating hours per year

$-

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

Sa

vin

gs

or

Re

ve

nu

e / y

r

$/kWh

Reliable electricity

Non-invasive to heat source & requires no major overhauls, no lubricants, and no operators

Savings or revenue

Electricity can be sold to the grid or used on-site to offset local consumption

No added fuel

Heat is the only input required for the Clean Cycle unit to generate electricity

Proven performance

Same basic unit is deployed regardless of heat source

*Assumes diesel engine fuel efficiency of 0.25L/kWh and 8,000 operating hours

No added emissions

The energy conversion process is closed loop and involves no combustion

Savings or revenue from 100kW ORC ($/yr)

12



Components of an installation

Heat source • Focus: recip

engines, boilers, turbines >1MW

Heat Capture • Exhaust gas heat

exchanger & damper

Heat Transfer • Controls water loop

that delivers heat to the Clean Cycle

Clean Cycle • Converts heat into

power

KEY

Existing plant

Clean Cycle & modular

components

Heat Rejection • Cooling system used

to condense the cycle’s working fluid

Example: reciprocating engine heat

13



Differentiators

Modular, package approach

• Goal is for installations to be like a Lego set:

• Install = Clean Cycle package + HPHW loop + heat source

Integrated Power Module

Reliability

• Turbine generator floats on non-contact magnetic bearings

• No gearbox, no external seals, no lubrication required to operate

Proven fleet in operation

• Accumulated over 200,000 operating hours

• >120 units shipped

Italy USA UK Romania Czech

Rep

Germany

Part 3:



GE ORegenTM

Fabio Sventurati

15



ORegenTM • ORegenTM is GE Organic Rankine Cycle

• System designed to recover waste heat energy from GT or similar waste heat sources water and CO2 free

• Developed for power gen application

• Mechanical drive application also possible

References

• #1 17MW system sold in Canada on a pipeline station – delivered in December 2012 – COD Fall 2013

• #3 17MW systems sold in China on 3 pipeline stations - delivery in March 2015 – COD August 2015

• #1 17MW system sold in Brunei on a powergen station – delivery in December 2014 – COD June 2015

• #1 17MW system sold in Thailand on a pipeline station – delivery in February 2015 – COD Summer 2015

16



Why waste heat recovery?

Simple

cycle GT

Air

Exhaust Gas Fuel

Waste

heat

GT simple cycle efficiency: 25÷40%

O&G GT mainly in simple cycle

Global trends: CO2 emission reduction

Increase efficiency

Increase in power demand

ORegenT

M

+ = Up to 17MW of power

recovery

77% of Oil and Gas installed Gas Turbines are in simple cycle

Wa

ste

hea

t

* ORegen is a trademark of Nuovo Pignone Spa and is available in selected markets

•Electricity production … sell back to grid

•Help comply with CO2-related

regulations

• Increase plant efficiency

Gas

Turbine

17



The Organic Rankine Cycle is a thermodynamic cycle based on the Rankine classic cycle using an organic working fluid

GE selected cyclo-pentane as working fluid

The ORC concept

Entropy [kJ/(kg°C)]

ORC cycle T-S diagram

50

100

150

200

250

-3 -2.5 -2 -1.5 -1

Te

mp

era

ture

[°C

]

T dew T bubble T cycle @ min p T cycle @ max p

Heaters

Expander

Recuperator

Condenser

Pump

Regenerator

Expansion

Condenser

Pump

Regenerator

Pre-heater

Vaporize

r

Super-heater

Working fluid selection by GRC Munich

Cyclo-pentane main characteristic

• Boiling point: 121°F (49.3°C)

• Freezing point: -137°F (-94 °C)

• Molecular Weight: 70.1

• Appearance: clear, colorless liquid

• No corrosion issue on plant equipment

18



ORegenTM plant schematic & scope of supply

Gas Turbine

The basic scope of supply for a typical

conversion includes the following:

• Organic Fluid C5H10 system

• Diatermic oil system

• Vaporizer & heat exchangers

• Turboexpander genset

• Condenser

• C5 and oil pumps

Exhaust

OIL HEATER

HEAT

EXCHANGERS

CONDENSER

Fan

C5 Pump

Cyclopentane loop

Diathermic Oil loop

Generator

Expander

Hot Oil Pump

RECUPERATOR

PGT25+ case study … overall plant efficiency up to 51%

19



Turboexpander (5-17 MW family)

16-blade wheels (17-4PH)

20



GT exhaust stack Diverter only interface

with GT

GT exhaust

stack

with ORegen

installed Control cab

Diathermal Oil piping

Waste Heat

Oil Heater

Turbo-Expander

C5 condenser

Cyclo-pentane island

ORegen™ Typical Layout

21



ORegenTM configurations

Parallel Oil

WHRU

#1

ORC Condenser

WHRU

n

GT#1

GT#n

GT#1 WHRU

ORC#1 Condenser #1

ORC#2 Condenser #2

Direct

Multi cycles Parallel Gas

To be defined as typical arrangement

To be scaled up / down from a standard design.

To be selected case by case. depending from the site conditions and project requirements

WHRU ORC Condenser

GT#1

WHRU ORC Condenser GT#1

- - - - - -

GT#n

22



GT Model GT Power

(KW)

Exhaust Flow

(Kg/sec)

Exhaust Temp

(°C)

GT Efficiency

(%)

ORC Output

(MWe)

System Efficiency

(%)

PGT25 (*) 23 261 68.9 525 37.7% 6.9 48.9%

PGT25+ (*) 31 364 84.3 500 41.1% 7.9 51.5%

PGT25+ G4 (*)

33 973 89.0 510 41.1% 8.6 51.5%

MS5001 (*) 26 830 125.2 483 28.4% 11.3 40.4%

MS5002B (*) 26 100 121.6 491 28.8% 10.8 40.7%

MS5002C (*) 28 340 124.3 517 28.8% 12.4 41.4%

MS5002D (*) 32 580 141.4 509 29.4% 13.8 41.9%

MS6001B (*) 43 530 145.0 544 33.3% 15.6 45.2%

LM6000 (**) 43 397 125.6 454 41.7% 9.7 51.1%

Reference data @ISO Conditions. 100% GT Turbine load

(*) Values at gas turbine shaft

(**) Values at generator terminals for LM6000PC coupled to 60 Hz generator

ORegenTM output in direct configuration

23



Designed for Unmanned operation No need of certified people to be 24h available at site

Turndown capabilities Best solution for GT partial load operation … @50% GT

load still 80% of power recovered

Highly reliable gas Expander as main unit

No blow down Negligible organic fluid consumption

No water requirement No water system treatment required

Efficiency Up to 13 points

C5 Bottom pressure Above atmospheric pressure, High Safety

(No O2 ingestion)

C5 Top pressure Below fluid critical pressure (No supercritical

operation), Best Power Recovery

Thermal Oil Great operability Range –35° ... +330°C

Condenser sized to handle uncondensable

Compact footprint, C5 condensing above atmosphere

Specific CO2 Decrease by 40%

Decrease CO2 specific emissions and generate up to 17 MWe

ORegen™ plant key cycle features

24 GE Confidential & Proprietary Information

GE © 2012 – All Rights Reserved

ORegenTM Produce up to 17MW electric power with no additional fuel by recovering heat from GT exhaust

• Efficiency improvement 20% … CO2 footprint 20%

• Carbon credits … singular enabler

• Cyclo-pentane as working fluid in a closed loop … no water!

24 GE Proprietary Information

GE © 2011 – All Rights Reserved

Super Critical CO2

Part 4:



Alternative Bottoming Cycle

Evolution

Dipti Dash

26



Advantages of CO2 as working fluid

• Low critical pressure & temperature

• Non-flammable, non-toxic, non-corrosive, thermally stable

• High density enables compact system

• Easily available and Inexpensive

Constant “Pinch” for SCO2

Why Supercritical CO2 ?

27



Generator

Heater~500°C

Recup 1

Condenser

250 bar

~300°C

250 bar

80 bar

• Configuration used by competitor Echogen

• Same as typical ORC configuration

• High (~30%) first-law thermodynamic efficiency

• Exhaust not fully utilized1~350°C

80 bar

GT exhaust heat

550°C

350°C

Poor efficiency on fuel-LHV basis

• Similar configuration to typical ORC

• 22-25% first-law efficiency

• Approx. 1/3 of exhaust exergy left

behind in exhaust stream

Uniqueness of CO2

High thermal stability

Non-flammable

May Condense for pumping

Small footprint

Low carbon footprint

Simple CO2 Rankine cycle

28



GE Proprietary Design:

Two, cascaded sCO2 loops for

better source utilization

Simple sCO2 cycle

Cycle layouts for heat recovery

29



System features:

• Non flammable working fluid

• higher efficiencies than ORCs

• No need for intermediate loop

• Compact turbo machinery

• 30% first-law efficiency

• Better utilization of exhaust energy

• 10% more power output compared to ORC

• Compact turbo-machinery with low footprint

Generator

Heater

Lo-T Recup

Mid-T Recup

Cooler/Condenser

A B

GT Exhaust

500°C

150°C

Compressor/

Pump

Low-pressure stream

High-pressure stream

GE advanced CO2 WHR cycle

30



Reheat CO2 vs Steam Rankine Cycle (A Case Study with 2XLM6000 CC)

Reheat CO2

Steam

Net Power : 137.5 MW

Efficiency : 49.31 %

Plant Cost (10th unit) : MM$ 146.6

No DM Water Plant, less O&M

More suitable for remote operation & fast start

Smaller foot print with once through cooling system

Net Power : 140.38 MW

Efficiency : 50.35 %

Plant Cost : MM$ 139.5

Matured technology

More efficient at high ambient

Reheat CO2 to cost MM13$ less to match Steam on LCOE basis*. Scope for further plant optimization and cost reduction through Expander, Feed Pump &

ACC * Fuel at $5/mmBtu

For more GE capabilities see GER 3430G at http://site.ge-energy.com/prod_serv/products/tech_docs/en/downloads/GER3430G.pdf

Contact your local GE Sales Application Engineer for help



http://site.ge-energy.com/prod_serv/products/tech_docs/en/downloads/GER3430G.pdf



dipti dash, kay kwok & fabio sventurati, ge

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