ORC Technology for

Waste Heat Applications

Presented at the Diesel Heat Recovery and
Efficiency Workshop December 11, 2007
Gwen Holdmann, Chena Power
Organic Rankine Cycle – Geothermal
Turbine Generator

R134a
Refrigerant

Heat Exchanger

Reinjected
Geothermal
Geothermal
Water (from
Water
production well)
United Technologies PureCycle 225

Pratt & Whitney Carrier Otis

UTC Fire & Security Aircraft Engines, Heating, Cooling Elevators,
Security & Gas Turbines & & Refrigeration Escalators &
Fire Protection Space Propulsion People Moving
Systems

UTC divisions span many markets and industries…

Sikorsky
UTC Research Center UTC Fuel Cells Hamilton Sundstrand Helicopters
– Technology On-site & Aerospace & Industrial
Advancement Transportation
Carrier 19XR2 Centrifugal Compressor
Centrifugal Chiller

Motor Compressor

Condenser

Evaporator/Cooler

Heat Out

Condenser

Compressor Motor
Throttle Valve

Evaporator/Cooler Power In

Refrigeration Cycle Heat In

VCC vs. ORC Cycle

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

Heat Out Heat In

Condenser Vapor Generator

Comp Motor Pump Turbine Generator

Expansion Valve
Power In Power Out
Evaporator/Cooler Condenser

Heat In Heat Out

Cooling Air Heat PureCycle

Conditioner ORC
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
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
 Typical Operating Conditions at Chena

250
8/23/07
200
Extremely stable operation: OILSUMPP (psia)
150 Pressures OILP (psia)
• Cold temp affects gross power. EVAP_P (psia)

• Hot temp doesn’t vary. 100 PUMPEXP (psia)

COND_P (psia)
• 99.4% availability 50

Averaged values – 8/23/07 0

CondEWT (F) 41.64 0:00:00 4:48:00 9:36:00 14:24:00 19:12:00 0:00:00
CondLWT (F) 49.88
EvapEWT (F) 162.97 180
EvapLWT (F) 131.88
160
EvapP (psia) 217.45 OIL_TSAT (°F)
140
CondP (psia) 62.80 EVAPTSAT (°F)
PumpKW (kW) 20.36 120 OILT (°F)
GenKW (kW) 196.09 100 Temperatures
WINDT (°F)
RefFlow (#/s) 23.22 LIQLINET (°F)
80
TsatEvap (F) 131.40 CONDEWT (°F)
60 EVAPEWT (°F)
TsatCond (F) 52.30
EVAPLWT (°F)
EvapGPM (gpm) 488.55 40
CONDLWT (°F)
CondGPM (gpm) 1666.98 20

0
0:00:00 4:48:00 9:36:00 14:24:00 19:12:00 0:00:00
 Atypical Operating Conditions at Chena
Alarm 26 High low side pressure
(High Oil Tsat) Condenser fans on
OIL TSAT over 110 deg
(inadvertent closure of 10 inch valve) Manual Control

250

200
RunState
150
OilSumpP
OilTsat
100
EvapExitP
50

0
12/23/20 12/23/20 12/23/20 12/23/20 12/23/20 12/23/20
06 18:28 06 18:43 06 18:57 06 19:12 06 19:26 06 19:40
Air Cooled Condenser

Added load of 24kW

when fans are running
UTC PureCycle 225 Product

ESTIMATED DRY CONDENSER

WEIGHT = 10,000 kg
(22,000 LBS)

ELECTRONICS

3.2m MAX
(10’- 4”)

TURBINE

EVAPORATOR

5.1m
2.1m (16’- 10”)
(7’- 5”)
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
Minimum Recip Size Requirements

2.5 MW Electricity

2.5 MWth rejected to

Jacket Water

2.5 MWth rejected to

exhaust
2.5 MW Diesel Genset

 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
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
 Chena Geothermal Power Plant
400
• Previous ORC units produced by 350
UTC used r245fa 300
Max working Pressure

Pressure (psia)
250 R245fa
• Using low-temperature 200
Maximum
boiling temp.
geothermal at 165 F required a 150 R134a r245fa and
r134a.
switch to r134a 100

50

• Also requires lower cold source 0

0 50 100 150 200 250 300 350
temperature (Chena has cold Saturation Tem p (F)

stream water available year-

round) PH Cycle Diagram for Chena Design TS Cycle Diagram for Chena Design

400 250.0
350
200.0
Pressure (lbf/in2)

Temperature (F)
300
250 150.0
200
100.0
150
100 50.0
50
0.0
0 0.20 0.25 0.30 0.35 0.40 0.45
60 100 140 180
Entropy (Btu/(lbm-R))
Enthalpy (Btu/lbm)
 X
600 F Biomass Configuration
Evap
Wellon 2.12 MW 118 psia,
536 F
Hot Oil 450 F 118 psia,
441 F

Recup. 8.4 psia, Turb

484 F 291 kW 243 kW net
118 psia, 8.4 psia,
11.5%
307 F 332F

Pump Cond
48 kW 1.872 MW

8.4 psia,
302F
220 F
D. Heating 290 F

300 psia,
290 F Evap 256 F
1.87 MW
Turb
300 psia, 25 psia, 225 kW 240 kW net
85 F, 16.3#/s 135 F
12.0%
Pump
27 kW Cond 80 F
Radiator
25 psia, 1.62 MW
83 F
60 F
 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