Organic Rankine Cycle (ORC) Waste Heat Generator (WHG) Presented by Grant Terzer and Marc Rouse 2010...
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Transcript of Organic Rankine Cycle (ORC) Waste Heat Generator (WHG) Presented by Grant Terzer and Marc Rouse 2010...
Organic Rankine Cycle (ORC) Waste Heat Generator (WHG)
Presented by Grant Terzer and Marc Rouse
2010 Regional Distributor Review & Conference
Americas
June 14-17, 2010
2
Waste Heat Generator (WHG)• Converts waste heat into electricity
– Capable of using ‘low grade’ waste heat
• Waste Heat Generator (WHG)
3
Turbines• Devices that convert 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)
4
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
• Inherent problem is
high latent heat of
water in liquid-vapor
phase change
5
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) 100°C (212°F) 15,6°C (60°F)
19,6 bar (270 psig) 212°C (413°F) 121°C (250°F)
6
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 burned to produce heat directly
– Not waste heat• A boiler creates heat for vaporization in a closed loop
system – not free fuel
7
The Complete System• Integrated
Power
Module
• Evaporati
ve
Condense
r
• Evaporat
or
• Heat
Source
• 375F
(190C)
• 3 MBTU/H
• Genera
te
• 125 kW
• R245fa
• Pump
8
How it Works - 1• Integrate
d Power
Module
• Evaporat
ive
Condens
er• Receiver
• Economi
zer
• Evaporat
or
• Liquid
• 85F
(29C)
• 230psig
(16bar)
• Heat
Source
• 375F
(190C)
• 3 MBTU/H
• Generat
e
• 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 fluid’s pressure is raised to the evaporating pressure.
9
How it Works - 2
• Evaporati
ve
Condense
r• Receiver
• Economi
zer
• Evaporat
or
• 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.
• Integrate
d Power
Module
• Generat
e
• 125 kW
• Liquid
• 85F
(29C)
• 230psig
(16bar)
• Liquid
• 85F
(29C)
• 26psig
(1.8bar)
10
How it Works - 3
• Evaporati
ve
Condense
r• Receiver
• Economiz
er
• Evaporat
or
• 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.
• Integrate
d Power
Module
• Generat
e
• 125 kW
• Liquid
• 118F
(48C)
• 220psig
(15bar)
• Liquid
• 85F
(29C)
• 230psig
(16bar)
• Liquid
• 85F
(29C)
• 26psig
(1.8bar)
• Integrate
d Power
Module
11
How it Works - 4
• Evaporati
ve
Condense
r• Receiver
• Economiz
er
• Evaporat
or
• 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 fluid’s 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.
• Generat
e
• 125 kW
• 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 - 5
• Evaporati
ve
Condense
r• Receiver
• Economiz
er
• Evaporat
or
• 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)
13
How it Works - 6
• Evaporati
ve
Condense
r• Receiver
• Economiz
er
• Evaporat
or
• 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)
14
How it Works - 7
• Evaporati
ve
Condense
r• Receiver
• Economiz
er
• Evaporat
or
• 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)
15
Applications• Turbines Exhaust
– Waste heat from exhaust
• Industrial Stack Gas– Refineries– Incinerators– Drying processes
16
Applications• Geothermal
– Water or Steam
• Solar Thermal– After steam process– Indirect evap source
17
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
19
Power Skid Components
• Receiver
• Pump
• Field
Connection
s
• Integrated
Power
Module
• Power
• Electronics
• Programmable
Logic Controller
(PLC) &
Magnetic
Bearing
Controller
(MBC)
• VFD for Pump
• Separator • Inlet
Control
Valve
• Bypass
Valve• Economiz
er• Separator
Drain
Valve
• Slam
Valve
20
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
21
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
22
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
23
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
24
Complete Installation
25
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
26
Available Power Output• More heat is
required for a given power production as condensing temp increases.
• Size heat source and condenser for ambient conditions.
• 125kW nominal is at generator terminals (inverter loss approx. 8 kW)
27
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.
28
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
29
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
– Assume net output is 110kW (due to system losses, heat source and condensing source.
• 500kW is produced, using no added fuel• new efficiency is
– (New power/old power)*old Efficiency = 37%• The ORC increases electric efficiency to over 37%
30
Case Study• Biomass boiler test site in the south east USA.
31
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
32
Technology Advantages• Very similar to those of Capstone MicroTurbines
High Speed Generator Increased Efficiency, Reliability, no gear box
Magnetic Bearings Increased Efficiency, Reliability, Reduced losses
Power Electronics Efficient variable speed operation
No lubrication or lubrication system Increased Reliability, Reduced parasitic losses, No contamination of process fluid
No coupling Increased reliability, fewer components
Variable speed operation Optimized cycle efficiency operating point
Hermetically sealed Higher reliability, fewer wear components
Single moving part Increased reliability
Modular Design Simple Integration into system (like standard piping)
33
For More Information• Contact Capstone Applications or Sales
Question & Answer