ORC: Field Installations and Future Potentialgpw.alaskaenergy.govtools.us/documents/support... ·...

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Energy Savings, Power Reliability, Environmental Stewardship

ORC: Field Installations and Future Potential

About UTC PowerPureComfort™

Solutions

PureCycle™

Solutions

PureCell™

Solutions

Project Profiles

Geothermal Energy GenerationIn Oil & Gas Settings

March 13-14, 2006

PureMotion™

SolutionsDepartment of Geological Sciences

Southern Methodist University

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ORC TechnologiesField Installations and Future Potential

Geothermal Energy Generation In Oil & Gas Settings March 13-14, 2006

Halley K. DickeySales Manager

Stationary Products

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Overview of Today’s Agenda

• Review UTC Power

• Review PureCycleTM ORC Technology

• Field Installations Data / Experience

• Future Demonstrations / Applications

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UTC Power Overview

UTC leadership spans many markets and industries…

Pratt & WhitneyAircraft Engines, Gas Turbines &

Space Propulsion

Carrier Heating, Cooling & Refrigeration

OtisElevators,

Escalators & People Moving

Systems

UTC Fire & SecuritySecurity &

Fire Protection

SikorskyHelicoptersHamilton Sundstrand

Aerospace & IndustrialUTC Research Center

– Technology Advancement

UTC Fuel CellsOn-site &

Transportation

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UTC Power Overview

Within those companies, a unique synergy was achieved...



Transportation

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UTC Power Overview


Carrier Heating, Cooling & Refrigerationwhich led to the formation

of UTC Power…


Transportation

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UTC Power Overview


which led to the formationof UTC Power…



Transportationand the introduction of

New CHP Technology Solutions…

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On-Site Power CHP Portfolio… unsurpassed in breadth and capability.

Combined Cooling, Heating, and Power

Fuel Free Power,Zero Emissions

Reliable, Durable, Ultra Low Emissions

240M 300M 360M

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Sustainable Energy Value Proposition

Avoided Emissions Per 1.0 MW application

650 48730003 x PureComfortTM 360M

24775035005 x PureCellTM 200

Equivalent number of

cars**Tons

Equivalent acres of forest*

Tons

Annual Avoided NOxEmissions

Annual Avoided CO2Emissions

9.5

4.8

70005 x PureCycleTM 200 1500 20.5 1000

*Each acre of forest assumed to absorb 1.3 tons Carbon/acre/year (Ref: International Panel on Climate Change)**Each car assumed to generate 38 lbm/NOx/year (Ref: US EPA)

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Organic Rankine Cycle Solutions

PureCell™• 200 kW + Net Power output• Zero fuel costs

Works on waste heat: gas or liquidNet effective heat rate reducer

• Zero emissions Fuel free means emission freeNet effective emissions reducer

• Extended high performanceYear round payback

Multiple Configurations

PureCycleTM - Heat to Power Systems

Efficient, Clean, Fuel Free Power Solutions

Developed in partnership with the DOE Office of Distributed Energy

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Modular Carrier ComponentsTurbine Generator – Carrier 19XR2™

Vapor Compression Cycle (VCC) Organic Rankine Cycle (ORC)

Oil Pump

ImpellerNozzle

TR

AN

SMISSIO

N

INLET

19 XR225 Radial Turbine

EXIT

Required Modifications

GeneratorINLET

ImpellerDiffuser

TR

AN

SMISSIO

N

EXIT

19 XR225 Centrifugal Compressor

Motor

Oil Pump

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

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Modular Carrier ComponentsTurbine Generator – Carrier 19XR2™

IMPELLERIMPELLERWHEELWHEEL

PIPEPIPEDIFFUSERDIFFUSER

IMPELLERIMPELLERWHEEL ASWHEEL ASTURBINETURBINEROTORROTOR

PIPEPIPEDIFFUSERDIFFUSERASASTURBINETURBINENOZZLENOZZLE

Compressor Operation:Cut-away Of Impeller (Spinning Clockwise)

and Pipe Diffuser (Radial Outward Flow)

Turbine Operation:Cut-away Of Impeller

(Spinning Counter-clockwise) and Pipe Diffuser

(Radial Inward Flow)

Adaptation of Existing Hardware - Compressor versus Turbine Operation

Impeller, nozzle and shroud – only changes to compressor

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PureCycleTM: Project Profiles

Past Field Installations:• US Energy – IL

Present Installations and Demonstrations:• Austin Energy – TX• UTRC - CT• Inland Empire Utilities Agency - CA• Seneca Meadows, NY• Chena Hot Springs – AK

Future Potential Applications:•Geothermal• Oil & Gas• Offshore Platform

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PureCycle™ 200 - Field Installations

• Over 7,000 Total Cumulative Hours @ 3 Sites• Gather Durability, Reliability and Performance Data • Test bed for product improvements – hard / soft

• Performance within +/- 3% of Predictions

Landfill Flare

Austin Energy (Austin, TX)

Landfill Recip Exhaust

US Energy (Danville, IL)

Process

UTRC (Hartford, CT)(2 units operating)

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PureCycleTM Field Tests: Purpose and Goals

UTC / UTRC / Field tested to:

• Gain operational experience • Gather reliability and performance data• Test product improvements:

– Remote operation / management / diagnosis– Controller and software modifications evaluation– Heat management control

• PureCycleTM experience– Lessons learned– Field experience

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Present Installations and Demonstrations:• Austin Energy – TX• UTRC - CT• Inland Empire Utilities Agency - CA• Seneca Meadows, NY• Chena Hot Springs - AK

Future Potential Applications:• Geothermal• Oil & Gas• Offshore Platform

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Landfill Reciprocating Engines – Danville, Illinois

US Energy / BioGasDanville, IL (Landfill)(3) J320 Jenbacher

• Commercial agreement - June 2003– US Energy

• Secured permits and approvals• Provides on-site technician support

– UTC Power provides turn-key installation via Carrier Service• One (1) year field trial period• Start-Up Q1, 2004

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Landfill Reciprocating Engines – Danville, Illinois

• (3) 987KW Jenbacher’s

• Extensive exhaust ducting

• Drawbacks:– Initiall design required all (3) engines operating to produce power.– Only (1) engine operating continuously– PureCycle’s availability – designed for (3) Jenbacher’s running.

• Lessons Learned: – Select sites with verified availability and capacity

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Economics

PureCycleTM – Air Cooled Condenser

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Landfill Flare – Austin, TX

• Municipal Solid Waste Facility• Commercial agreement - June 2003• Installation/design - third-party engineers - Sept 2003• Start-Up Q1, 2004• Unattended operation began late March 2004

• Still operating today …

Austin EnergyAustin, TX (Landfill)Open Flare

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Austin EnergyAustin, TX (Landfill)Open Flare

• Attached to a candle flare• Separate Heat Recovery System (HRS) required• Drawbacks:

– Flare instability delayed completion… hampers current operation

• Lesson Learned - Know your heat source

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28-31, July 05

Average Power Index: 1.03

Average Heat Index: 0.70

Average Ambient Temp: 82oF

Max Net Power: 164.7 KW

Operating Hours: 68.1

Heat Source Availability: 1.0

Run Time Availability: 0.95

Gross Availability: 0.95

09 - 14, August 05

Average Power Index: 1.02

Average Heat Index: 0.78

Average Ambient Temp: 83oF

Max Net Power: 203.7 KW

Operating Hours: 126

Heat Source Availability: 0.98

Run Time Availability: 1.00

Gross Availability: 0.97

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Inland Empire Utilities Agency – Chino, CA

• Commercial agreement - June 2005• Startup September 06• Scope:

– IEUA• Secures permits and approvals• Installation and interconnection

– UTC Power• Equipment and support

IEUAChino, CAAnaerobic Digester Gas Reciprocating Engines

• LEED Platinum Facility (1 of 3)• Largest manure digester in the world• Premium CHP technology showcase:

• ORC• ADG Reciprocating engines• ADG Microturbines• Absorption waste heat cooling• Sterling engine• ADG Fuel cells (future)

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Inland Empire Utilities Agency – Chino, CA• ADG Reciprocating Engine Exhaust - (2) CAT G3608’s• Waste heat at ~ 8500 F• ~ 200 KW Output• Using Waste Heat from Water Cooled Condenser:

• Providing hot water to laundry customer• Raise 500 GPM - 250F

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w/o CHP - Condenser Water Heat Recovery – 250F Delta T

• Recover waste heat from engines…

• Offset retail electric rates … produce Clean Power– At $0.14/kWh and 8,000 hr / yr = $200,000 Annual Savings.

Net Annual Savings Over $ 200,000.

• Potential for: Renewable energy credits / State incentives

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w/o Condenser Water Heat Recovery – 250F Delta T

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CHP - Condenser Water Heat Recovery – 250F Delta T

• Recover waste heat• Offset gas consumption… produce Hot Water

– Temp increase: 250F - 500 gpm = 6.25 MMBtu/hr– At $8/MMbtu and 8,000 hr / yr = $380,000 Annual Savings.

• Offset retail electric rates … produce Clean Power– At $0.14/kWh and 8,000 hr / yr = $200,000 Annual Savings.–

Net Annual Savings Over $ 580,000.

• Potential for: Renewable energy credits / State incentives

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Condenser Water Heat Recovery – 250F Delta T

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Seneca Meadows – NY

• Ship Q3, 2006

• Integrated Combined Heat Power– Utilizing the ORC Heat Rejection– Heating Tomato Hot House

Seneca Meadows, NYReciprocating EnginesTomato Hot House

Reciprocating Engine Integration Seneca Meadows, NY

>20MW

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Chena Hot Springs – AK

Geothermal Power Chena Hot Springs, Alaska

>400MW

Water Temperature at Surface

Less than 200Greater than 200

Chena Hot Springs

• Ship April 15, 2006• Lowest Geothermal Temperature

Application of ORC in the World• Premium CHP technology showcase:

– ORC– Aqueous Ammonia Absorption– Biomass– Hydrogen

Chena Hot Springs, AKGeothermal Resource

• Geothermal Temp: 1650 F• Cooling Temp: 380 F• Working Fluid: R134a

Office of Geothermal Technologies

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Carrier Condenser

Carrier Evaporator

CarrierGenerator

CarrierTurbine

Pump

Carrier SupplierPump Inverter

Carrier SupplierControl Panel

Carrier SupplierPowerElectronics

* 90% Carrier COTS

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Mar02,06 - b: Water temperatures only

40

60

80

100

120

140

160

180

12:00:00PM

1:12:00PM

2:24:00PM

3:36:00PM

4:48:00PM

Tem

pera

ture

(F)

CondEWTEvapEWTCondLWT

Mar02,06 - b (Generator power - Ref. Pump Power)

-50

0

50

100

150

200

250

12:00:00 PM 1:12:00 PM 2:24:00 PM 3:36:00 PM 4:48:00 PM

Net

Pow

er (k

W)

Power consumed by pump before generation.

Greater than 200 kW net power…

… even though cold water is ~10F warmer than Chena.

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Offsetting diesel powered generation costs ~ $0.30 / kwh

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Geothermal and Oil & Gas Markets

• Small Binary plant for low to med temp• Deployed on a distributed basis• Develop resource - positive cash flow• Could be well head - or centralized• Abandon/capped: 200-250+0 F

Oil & Gas Locations

Geothermal

• Small Binary plant for low to med temp• Deployed on a distributed basis• Develop resource - positive cash flow• Could be well head - or centralized• Abandon/capped: 200-250+0 F

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Offshore Oil & Gas Platform

• Utilizing hot liquid resource– Hot oil– Hot water– Enhanced production

• Utilizing seawater for condensing - at or below thermocline– Increased ORC cycle efficiency– Utilize lower temperature resources (thermocline: 530 F @ 500’, 430 F @ 1000’)– Offset platform base load electrical energy requirements– Utilize the ORC Heat Rejection for on-platform heating

Offshore PlatformsORC Power GenerationHot Liquid Resource

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Plan of Action – what’s next?Near-term focus: demonstrate reliability on geothermal resource

• Pick fruit off the ground…– Existing oil & gas wells w/ water injection– Pumping hot liquid: 200 – 250 – 300+ 0 F– Pumping wells with diesel power– Customer side of the meter: $0.17 - $0.30 (payback @ < 1.0 year)

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• Pick fruit off the ground…– Existing oil & gas wells w/ water injection– Pumping hot liquid: 200 – 250 – 300+ 0 F– Pumping wells with diesel power– Customer side of the meter: $0.17 - $0.30 (payback @ < 1.0 year)

• Pick low hanging fruit…– All power consumed on site– Pumping hot liquid: 200 – 250 – 300+ 0 F– Customer side of the meter: $0.08 - $0.12 (payback @ < 3.0 years)

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• Pick fruit off the ground…– Existing water injection– Pumping hot liquid: 200 – 250 – 300+ 0 F– Pumping wells with diesel power– Customer side of the meter: $0.17 - $0.30 (payback @ < 1.0 year)

• Pick low hanging fruit…– All power consumed on site– Pumping hot liquid: 200 – 250 – 300+ 0 F– Customer side of the meter: $0.08 - $0.12 (payback @ < 3.0 years)

• Get a short ladder…– Export to the grid– Pumping hot liquid: 200 – 250 – 300+ 0 F– Utility wholesale purchase: $0.06 - $0.07 (payback @ < 5.0 years)

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[email protected]

(909) 838-6235

Thank you.Geothermal Energy Generation In Oil & Gas Settings

Department of Geological Sciences - Southern Methodist University

mailto:[email protected]

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