Organic Rankine Cycles for Waste Heat Recovery

NASA/C3P - 2009 INTERNATIONAL WORKSHOP ON ENVIRONMENT AND ALTERNATIVE ENERGY Global Collaboration in Environmental and Alternative Energy Strategies 11. November 2009

Dr. Thomas Frey GE Global Research Center Munich (GRC)

Waste Heat Recovery Overview

What is Waste Heat Recovery (WHR)?

Benefits CO2-free additional power Increased plant / process efficiency Fuel savings Driving forces Fuel, electricity prices / incentives CO2 or emissions constraints Grid independence Key CTQ: CAPEX ($/kW)
Heat Source
Qin

WHR System Power Qout

Heat Sink

Capturing low grade heat sources for energy production

Copyright 2009 General Electric 3/ Waste Heat Recovery / 12/7/2009

Waste Heat Recovery Segments

New Technology ... Heat Recovery Program Focus Conventional GE Technology

Geothermal
100C

Industrial
200C

Solar
300C

Engines & Gas Turbines

400C 500C

Large GT
600C

Advanced Heat Recovery Technologies Conventional Steam Cycles

Geothermal & Solar

100 GW geothermal potential (MIT)* 200 GW solar potential*

Industrial Waste Heat

Approx. 950 PJ heat losses (100-200C)* $6 B/yr energy wastes* Refineries, cement, pulp & paper,

Reciprocating Engines
Approx. 5% pts efficiency boost Reduced fuel consumption & emissions

Gas Turbines
WHR adds up to 20% power
(* US only)

Green, CO2 free technology

Copyright 2009 General Electric 4/ Waste Heat Recovery / 12/7/2009

Waste Heat Recovery Organic Rankine Cycle (ORC)

Organic Rankine Cycle

Heat Source

Cycle Principle Expansion of organic fluid Features Robust, simple system Mature, well known components Only low temperatures required On-site operators not required
Pressurised liquid

BOILER

ORC
Fan Power

Nearsaturated vapour Shaft Work

CONDENSER Pump Power

Technology Status Conventional ORCs successfully in operation for many years CAPEX: ~ 2000 6000 $/kW, f (kW, temp, site etc.)

Advantaged technology for small and low T applications

Copyright 2009 General Electric 6/ Waste Heat Recovery / 12/7/2009

ORC Efficiency
Carnot efficiency Theoretical maximum Increases with increasing T Real efficiency Process always has losses 30 50% of Carnot Potential improvements Reduce losses Increase max. temperature (risk: fluid decomposition) Optimize cold cycle end (increased cost)
60 50 Carnot efficiency / % 40 30 20 10 0 50 100 150 200 250 300 350 400 Temperature of heat source Th / C

Carnot efficiency:

C = 1

Th Tc

Tc=20C

Tc=40C

Copyright 2009 General Electric

7/ Waste Heat Recovery / 12/7/2009

Waste Heat Recovery Example: ORC for Reciprocating Engines

Gas Engine Heat Sources

Mechanical power 540 kW

1415 kW electrical power

Fuel

MW 3,4 MW

Exhaust Gas Exhaust Inter Cooler Intercooler Jacket Water Water Oil Oil

600 kW @ 472 (180)C

J 420 GS-A25 Biogas

218 kW @ 160C

160 kW @ 90C

432 kW @ 95C

Challenges for waste heat recovery

Use which sources? High specific cost due to low power Thermal integration into engine

~810 kW ~95C LT heat

~600 kW ~472C HT heat

Two heat sources with different temperature level

Copyright 2009 General Electric 9/ Waste Heat Recovery / 12/7/2009

Example: GE Jenbacher Recips WHR

Reciprocating engine Containerised ORC

Medium Engine power Fuel ORC power boost Efficiency increase 1 1,5 MW Biogas, landfill, NG 110 - 140 kW > 4% pts Specifications

Large 3 MW Natural Gas 300 - 370 kW > 5% pts

ORC: Bottoming cycle for reciprocating engines

Copyright 2009 General Electric 10 / Waste Heat Recovery / 12/7/2009

GRC Waste Heat Recovery Focus

Reciprocating Engines
Customer prototype installation Q1/2010 Approx. 5% pts efficiency boost Potential for 50%+ efficient engine

Industrial Gas Turbines

GE O&G ORegenTM cycle developed ORC adds approx. 20% power to GT Ecomagination certified
Real Fluid Cycle
T Vapor dome

Industrial Waste Heat

Collaboration with industry (e.g. utilities, cement, refineries etc.) Identification of new WHR opportunities & markets

Ideal (trilateral)

Real

Discovery

Development of high efficient cycles New fluids identification CAPEX optimized components Simulation & experiments

Key to low $/kW: New cycles & integration into heat source
Copyright 2009 General Electric 11 / Waste Heat Recovery / 12/7/2009

Thank you.

Acknowledgement: Project is partly funded by the Bavarian Ministry for Economy, Infrastructure, Traffic and Technology

Copyright 2009 General Electric

12 / Waste Heat Recovery / 12/7/2009