ORC Technology for

Waste Heat Applications

Presented at the Diesel Heat Recovery and

Efficiency Workshop December 11, 2007

Gwen Holdmann, Chena Power

Heat Exchanger

GeneratorTurbine

R134a

Refrigerant

Reinjected

Geothermal

Water

Geothermal

Water (from

production well)

Organic Rankine Cycle – Geothermal

UTC Research Center

– Technology

Advancement

Hamilton Sundstrand

Aerospace & Industrial

Pratt & Whitney

Aircraft Engines,

Gas Turbines &

Space Propulsion

Sikorsky

HelicoptersUTC Fuel Cells

On-site &

Transportation

Otis

Elevators,

Escalators &

People Moving

Systems

Carrier

Heating, Cooling

& Refrigeration

UTC Fire & Security

Security &

Fire Protection

UTC divisions span many markets and industries…

United Technologies PureCycle 225

Compressor

Evaporator/Cooler

Condenser

Heat Out

Heat In

Throttle ValveMotor

Power In

Refrigeration Cycle

Centrifugal Chiller

Evaporator/Cooler

CompressorMotor

Condenser

Carrier 19XR2 Centrifugal Compressor

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

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

Air

Conditioner

CoolingPureCycle

ORC

Heat

VCC vs. ORC Cycle

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

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

Chena Geothermal Power Plant

0

20

40

60

80

100

120

140

160

180

0:00:00 4:48:00 9:36:00 14:24:00 19:12:00 0:00:00

OIL_TSAT (°F)

EVAPTSAT (°F)

OILT (°F)

WINDT (°F)

LIQLINET (°F)

CONDEWT (°F)

EVAPEWT (°F)

EVAPLWT (°F)

CONDLWT (°F)

0

50

100

150

200

250

0:00:00 4:48:00 9:36:00 14:24:00 19:12:00 0:00:00

OILSUMPP (psia)

OILP (psia)

EVAP_P (psia)

PUMPEXP (psia)

COND_P (psia)

Temperatures

Pressures

Extremely stable operation:

• Cold temp affects gross power.

• Hot temp doesn’t vary.

• 99.4% availability

8/23/07

Averaged values – 8/23/07

CondEWT (F) 41.64

CondLWT (F) 49.88

EvapEWT (F) 162.97

EvapLWT (F) 131.88

EvapP (psia) 217.45

CondP (psia) 62.80

PumpKW (kW) 20.36

GenKW (kW) 196.09

RefFlow (#/s) 23.22

TsatEvap (F) 131.40

TsatCond (F) 52.30

EvapGPM (gpm) 488.55

CondGPM (gpm) 1666.98

Typical Operating Conditions at Chena

0

50

100

150

200

250

12/23/20

06 18:28

12/23/20

06 18:43

12/23/20

06 18:57

12/23/20

06 19:12

12/23/20

06 19:26

12/23/20

06 19:40

RunState

OilSumpP

OilTsat

EvapExitP

OIL TSAT over 110 deg

(inadvertent closure of 10 inch valve)

Alarm 26 High low side pressure

(High Oil Tsat) Condenser fans on

Manual Control

Atypical Operating Conditions at Chena

Added load of 24kW

when fans are running

Air Cooled Condenser

CONDENSER

ELECTRONICS

TURBINE

EVAPORATOR

3.2m MAX

(10’- 4”)

ESTIMATED DRY

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

5.1m

(16’- 10”)2.1m

(7’- 5”)

UTC PureCycle 225 Product

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

2.5 MW Diesel Genset

2.5 MW Electricity

2.5 MWth

rejected to

Jacket Water

2.5 MWth

rejected to

exhaust

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

Minimum Recip Size Requirements

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

PH Cycle Diagram for Chena Design

0

50

100

150

200

250

300

350

400

60 100 140 180

Enthalpy (Btu/lbm)

Pre

ssu

re (

lbf/in

2)

TS Cycle Diagram for Chena Design

0.0

50.0

100.0

150.0

200.0

250.0

0.20 0.25 0.30 0.35 0.40 0.45

Entropy (Btu/(lbm-R))

Te

mp

era

ture

(F

)

0

50

100

150

200

250

300

350

400

0 50 100 150 200 250 300 350

Saturation Temp (F)

Pre

ssu

re (

psia

)

Max working Pressure

R134a

R245fa

Maximum

boiling temp.

r245fa and

r134a.

• Previous ORC units produced by

UTC used r245fa

• Using low-temperature

geothermal at 165 F required a

switch to r134a

• Also requires lower cold source

temperature (Chena has cold

stream water available year-

round)

Chena Geothermal Power Plant

Wellon

Hot Oil

Evap2.12 MW

Pump48 kW

Turb291 kW

Cond1.872 MW

Recup.

Evap1.87 MW

Pump27 kW

Turb225 kW

Cond1.62 MW

D. Heating

Radiator

118 psia,

536 F

8.4 psia,

484 F8.4 psia,

332F

8.4 psia,

302F

118 psia,

307 F

118 psia,

441 F

600 F

450 F

220 F290 F

25 psia,

135 F

300 psia,

85 F, 16.3#/s

25 psia,

83 F

80 F

60 F

290 F300 psia,

256 F

240 kW net

12.0%

XBiomass Configuration

243 kW net

11.5%

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