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CONTENT

1. Industrial Waste Heat- Why & How- Recommendations of


International Chamber of Commerce-November 2009- on Energy
Saving International Policy
2. Ways for Improvement- Case Studies
3. Pakistan- Actual Energetic Situation and Perspectives
4. Industrial Processes Waste Heat Recovery

Thermo-electricity

Thermo-acoustics

Stirling Engines

Fuel Cells

Heat Recovery from Heavy Diesel Engines

Industrial actual applications-CHP & ORC

Pentane Cycle (CCLC)


5. Gas Turbines Exhaust Heat Recovery

Combined Heat-Power Cycle

Organic Rankine Cycle

Fluids selected in ORC

Economical aspects of both Cycle types and comparison


6. Case Studies- Application on Gas Pipelines Compression Stations
7. Providers for Technology and Equipment
2

INDUSTRIAL HEAT
RECOVERY
Why & How

MONEY STARTED TO HAVE NOT SO MUCH VALUE AS THE RESOURCES.


HUMANKIND DID NOT CREATED THE EARTH RESOURCES, ONLY
EXPLOITED THEM.
DIMINISHMENT OF RESOURCES WILL BECOME THE MOST IMPORTANT
FACTOR FOR THE WORLD ECONOMIC EVOLUTION AND A MAIN REASON
FOR THE NEXT FUTURE TECHNOLOGICAL REVOLUTION,
THIS NEXT FUTURE ALREADY STARTED!
To add:
Consulting activity organization
Spain ORC
Spain comparative analyze
Elaborated Energy Cost and perspectives

INTERNATIONAL CHAMBER OF
COMMERCE

WAYS FOR IMPROVEMENT


EDUCATION & TRAINING

Details on:

PROVIDING ENERGY EFFICIENCY AS A SERVICE

GOVERNMENTAL SUPPORT

BETTER COMMUNICATION

RAISING AWARENESS OF ENERGY CONSUMPTION &


OPPORTUNITIES

ALWAYS CONSIDERATION TO LIFE-CYCLE COST

PAKISTAN ENERGETIC
SITUATION

Source: INDIVIDUAL RESEARCH PAPER of Prof.

Installed Generating Capacity (2008)

PAKISTAN Present Energy Demand

D em an d (M W )

17,000
15,838

16,000
15,000

13,847

14,000
12,595

13,000
12,000

16,056

11,285

11,000
10,000

200304

200405

200506

200607

200708

Historical Surplus/ Deficit (2002 2007)


WAPDA SYSTEM
YEAR

Installed
Capacity

Firm
Capability

Computed Peak
Demand

Surplus/
Shortfall

2001-02

15819

10894

10459

435

2002-03

15819

10958

11044

-86

2003-04

17299

11834

11598

236

2004-05

17350

12792

12595

197

2005-06

17400

12600

13847

-1247

2006-07

17366

13292

15838

-2546

Continuous and critical increase of the Energy Deficit since 2005


18

Saving Potential in Energy demand


INDUSTRIAL SECTOR

SAVING POTENTIAL (%)

AGRICULTURE

15-20

PAPER

15-25

GLASS / CERAMIC

20-25

COMMERCIAL BUILDING

10-25

FOOD & BEVERAGE

10-30

TEXTILE

14-30

FERTILIZER

16-30

CEMENT

20-40

IRON / STEEL

23

PETROCHEMICAL

35

DOMESTIC
PUBLIC UTILITY SERVICES

10-15
10

FUTURE GENERATION PROJECTS*


(2008-2011)
Type

Installed
Capacity
(MW)

Expected
COD

IPP

227

Jun. 2010

Nishat Chunian Project


2010-11 Allai Khwar HPP

IPP
Public

200
121

Jun. 2010
Jul. 2010

C.C. at F/Abad

Public

125

Nov. 2010

C.C. at Dadu

Public

125

Nov. 2010

Nandipur Power project

Public

425

Dec. 2010

Bhikki Power Project

IPP

225

Dec. 2010

Western ElectricProject

IPP

150

Dec. 2010

Green Power Project

IPP

205

Dec. 2010

KAPCO Extension

IPP

400

Dec. 2010

HUBCO Narowal

IPP

225

Dec. 2010

Liberty Power

IPP

200

Dec. 2010

Fiscal
Year

Name of Project

Engro Power Project

*Based on WPPO information dated 25 April 2008

Capacity
Added in
each Year
(MW)

Total
Installed
Capacity
(MW)

4856

26965

20

PROCESS RESIDUAL HEAT


RECOVERY

Heat Industrial Sources for Recovery


Flare and Open Vent Streams rather than the actual technology of
compression-accumulation of gas and use for peak activities, following a
well balanced account of potentiality, Applicable to all wellheads, Refineries
and Gas Processing Plants (>80%)
Industrial Owens in any Industry (Petrochemicals, Cement, Fertilizers,
Glass)- with extremely high potential of Heat Recovery (>80%)
Gas Turbine Exhaust from Compression and Pump Stations, Power Plants
and all other users of such drivers (>50%)
Gas Engine Exhaust in similar conditions as above (>50%)
Residual Heat from Process Fluids, instead of cooling required within
process, heat to be transferred to motive fluids

Recovery Cycles
Power and Heat Generation- CHP (combined Heat and Power)whenever Heat is required for Process fluids as heating input, or in
housing estates for winter season heating. In Oil & Gas Industry, best
samples are Refineries and Gas Processing Plants (e.g. Heating Oil
used for Amine Regeneration). Pipelines are recommended for this
cycle only when the neighboring Communities need Heat (steam).
Power Only- the best as efficiency and Cost Recovery Cycle- Organic
Rankin Cycle (ORC) is the actual implemented in the most of residual
heat sources. Motive fluids recovering the heat are not water
(vaporization temperature 100C) , but organic fluids (propane,
ammonia, other refrigerants) having the vaporization temperature a few
degrees C (propane +15 C). This is allowing to recover heat from lowlevel heat sources.

Recommended Equipment as Power Generation


Drivers
Thermoelectric Generators (15-550W)- Best for small amounts of
Power. Low efficiency. Remote sites.
Microturbines (30-75 kW). Not sensitive as availability to the quality or
flow variation
Reciprocating Engine Genset (55-3000 kW)- best for displacing Power
Costs at electrified sites
Gas Turbines (500-30,000kW) -Best for Centralized Long-Term Power
Generation
Fuel Cell and Combinations- to be considered for next Future, as the
technology is improving very fast- Bloom Boxes no need distribution
systems, working as independent, self-generating systems for a local
user.

INTEGRATED SYSTEMS
Thermo-electricity : 20% announced fuel economy Efficiencies of conversion
depend from difference of temperature and characteristic of used materials
(two metals). Can produce a few tent of kW at voltage 60 to 400 V. Cost still
very high (2005 price 1$/W)
Thermo-acoustics : low specific power (home appliances)
Fuel Cells The famous Bloom Box are already used for Commercial
Companies electricity Supply (Adobe,
Stirling Cycle in co-generation : up to 40% announced fuel economy
but a too low specific power
Systems for Heavy Diesel Engines
Electrical Turbo-Compounding (Caterpillar): 3 to 10% announced fuel
economy
Systems for heavy Industrial Applications
Rankine Cycle (CHP): Turbo-steamer : 17% announced fuel economy
(recommended when Steam is required for Process or Housing)
Organic Rankine Cycle (ORC) : up to 60% announced fuel economy (the
most efficient recovery process, main subject of presentation)

Electric turbo-compounding
The electric turbo-compounding as under development by Caterpillar uses the
turbocharger shaft for extracting power from the exhaust gas. The power take
off is obtained by a little generator that is located between turbine and
compressor. The announced fuel consumption reduction is in the order of 3 to
5% on cycle and up to 10% for the peak values. Caterpillar considers this a
concept with high customer value. Potential important users are not only the Trucks,
but Aboveground Mining Heavy Equipment also, heavy continuous loads being impacted by
important fuel savings- see next

Source: www.heat2power.com

Electric turbo-compounding Fuel savings

Source: www.heat2power.com

GAS TURBINE EXHAUST HEAT


RECOVERY
COMBINED (HEAT +POWER)
CYCLE

CHP CO-GENERATION BY CAPSTONE

29

CHP EQUIPMENT COST CALCULATION


Estimated Capital Costs for
Typical Gas Turbine-Based CHP
Systems ($000s) Cost
Component
Nominal Turbine Capacity (MW)

System 1

System 2

System 3

System 4

System 5

10

25

40

Equipment (Thousands of 2010 $)


Combustion Turbines

$1,078.84

$2,904.91

$6,485.82

$13,551.98

$25,190.73

Electrical Equipment

$436.85

$573.97

$694.07

$1,105.42

$1,674.07

Fuel System

$176.44

$188.13

$199.83

$266.79

$380.52

$78.65

$191.32

$311.43

$393.27

$442.17

Water Treatment System


Heat Recovery Steam Generators

$539.95

$653.68

$828.00

$1,094.79

$1,319.06

SCR, CO, and CEMS

$0.00

$0.00

$0.00

$0.00

Building

$0.00

$0.00

$0.00

$0.00

$2,309.68

$4,513.07

$8,519.14

$16,411.18

$29,006.54

$817.37

$1,490.19

$2,729.53

$5,258.17

$9,294.00

$3,127.05

$6,003.26

$11,248.67

$21,669.34

$38,300.54

$288.05

$427.29

$705.77

$1,359.45

$2,402.15

Total Equipment
Construction
Total Process Capital
Project/Construction Management
Shipping

$49.96

$94.60

$174.32

$336.94

$594.16

Development Fees

$230.65

$451.73

$852.45

$1,641.12

$2,900.65

Project Contingency

$123.30

$188.13

$293.36

$565.46

$999.13

Project Financing

$244.47

$458.11

$849.26

$1,636.87

$2,892.15

$4,062.40

$7,623.12

$14,123.82

$27,208.11

$48,088.78

1222.335

$5,800.25

$10,883.03

$24,795.33

$49,484.37

$3,533.08

$1,396.65

$1,379.64

$1,166.00

$1,033.14

Total Plant Cost


Actual Turbine Capacity (kW)
Total Plant Cost per net kW

All reference site 2007 prices have been adjusted for 2010 as per NASA Inflation Index 2003

30
http://www.epa.gov/chp/documents/catalog_chptech_gas_turbines.pdf

GAS TURBINE EXHAUST HEAT


RECOVERY

ORGANIC RANKINE CYCLE (ORC)

ORC Technology

32

ORC Process-Brief description


In an ORC, another working fluid, typically one chosen because it has a
lower freezing temperature and other desirable properties, goes through
the same four-step Rankine cycle process as a steam system.
In the ORC, the use of a recuperator and an intermediate heat transfer
fluid widens the choice of the working fluid to optimize the heat-to-power
efficiency and provides additional safety for the system operations.
This intermediate fluid (thermal oil) is used in the waste heat oil heater
(WHOH) to capture the waste heat from the turbine exhaust gas. The
thermal oil selection is based upon low operating pressures, stability, and a
low freezing point. The hot thermal oil from the WHOH is fed into the
vaporizer and preheater of the ORC where its thermal energy is
transferred to the Rankine cycle's working fluid.
Many compounds such as chlorofluorocarbons, ammonia, and
hydrocarbons (like propane or pentane) can be used to match the Rankine
cycle to the level of heat available. The properties of working fluid shall
match the efficiency through its thermodynamic properties and the use is
conditioned by actual Environmental Laws to have a limited environmental
impact.
33

ORC Site Arrangement

D
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AP SE
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TU
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GA
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N
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RB

GE
NE
RA
T
DU
C

OR

Economic analysis (payback time)

Cost of ORC unit = $128,000

Fuel efficiency = 14 kW-hr/gal, Operation = 24 hr/day

36

37

38

39

40

COST ELEMENTS OF HEAT


RECOVERY

41

ACTUAL COST OF ELECTRICITY, BY SOURCES


OCT.2010 (USD/MMBTU)

http://www.acore.org/files/publications/ACORE_USonly_Q_REVIEW_low4.pdf
42

43

44

ORC in Europe- GMK

http://www.gmk.info/ORC_waste_heat.523.html

45

location:

initial
operation:

operating company:

heat source:

Central Germany

Beginning
2010

Industrial client

Industrial waste
INDUCAL
heat

Zehna

2009

BioCon Invest

BioGas engine INDUCAL IC60 50 kWel

module:

electric output:

570 kWel

46

SUMMARY of LESSONS LEARNED TESTING an ORC on


PIPELINE COMPRESSION STATION (St. Anthony, ND, USA)
Lessons learned that may be useful for evaluating future ORC plant opportunities include:
* When operating at full recovered heat input, the ORC plant consistently delivered 5.5 MW
or more output to the grid at up to 15% conversion efficiency (net electricity output/recovered
heat input).
The ORC plant improved the overall energy efficiency by 28%, from 32% simple cycle
efficiency to 41% for the combined system. The system entered its second year of operation
with the expectation of consistently achieving near 100% availability when the pipeline
compressor is operating.
* There is an economic model that makes existing ORC technology applicable to pipeline
compressor stations cost-competitive with other generation technologies.
* Remote pipeline-based ORC systems can provide Base-Load power.
* Cold ambient operation provided challenges, including the need to replace frozen flow
transmitters and change certain valve designs that were prone to freezing.
* There was minimal environmental impact, minimal permitting, and virtually zero
incremental emissions related to the compressor station installation.
* The pipeline compressor was shut down several times during the test period due to market
demand fluctuations. Since compressor downtime affects annual waste heat availability and
base-load power output, it is important to obtain good estimates of annual compressor run
hours from the pipeline when selecting project locations.
* The operating constraints identified were: heat input (temperature and mass flow) that was
dictated by the gas turbine's operation, the limit on minimum WHOH outlet exhaust gas
temperature to prevent condensation, and the maximum thermal oil operating temperature
limit.
COPYRIGHT 2009 American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc

47

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ORC Technology

Refrigerant properties
List of Providers

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Qualified Energy Recovery


A Green Power Technology
No additional fuel consumption
Near zero emissions with air cooled OEC
Inside the fence installation on existing sites.
No water consumption with closed loop operation
No creation or disposal of waste
Displaces fossil fuel based energy
No new transmission required

Qualified Energy Recovery


A Green Power Technology
NEVADA: AB 429 accepts Qualified Energy Recovery from non electrical generating sources
such as mining processes, as eligible for RPS
NORTH DAKOTA: Pipeline Compressor GT Exhaust Gas Energy Recovery Is eligible for green
tags or green energy sales
SOUTH DAKOTA: Consider these projects as renewable energy resources
OTHERS: Under Consideration in Many States

Heat Sources
Industrial and Process Plants

Cement, Glass, Petrochem, Mining, Metals, et al


Gases; >400F (204C)
Liquids; >200F (93C)
LP Steam; any
250kW to 10 MW (per module)
Gas Pipeline Compressor Stations
Gas Turbine Exhaust

Recovered Heat Power Generation


ORMAT Energy Converter
Organic Rankine Cycle
Efficient, Cost-Effective, Reliable
Greater than 98% availability
Totally Waterless
No blowdown, disposal, or make-up
Air-cooled condenser
Fast, easy permitting
Unattended, Remote Operation

ORMAT SELECTED ENERGY RECOVERY PROJECTS


PROJECT
NAME

LOCATN

MW

YEAR

ORMAT ROLE

OWNER
OPERATOR

Neptune Gas

Luouisia
naUSA

MW 4.0

2003

EPC equipment
for recovery of
heat from
turbine exhaust

Enterprise Partners
.LLC

Heidelberger
Cement

Germany

MW 1.5

1999

Heidelberger
Cement

Gold Creek

Canada

MW 6.5

1999

Design/supply of
equipment for
recovery of heat
from clinker
cooler
Design/supply of
equipment for
recovery of heat
from gas turbine
exhaust

Minakami

Japan

KW 600

1998

Design/Supply of
equipment for
recovery of heat
from MSW
Incinerator

Ishikawajima
Hanyoki Service

TG2 Kawerau

New
Zealand

MW 3.5

1993

Bay of Plenty
Electric Power
Board

China

MW 1.3

1993

Design/Supply of
equipment for
recovery of heat
from Paper
Process
Design/Supply of
equipment for
recovery of heat
from MSW
Incinerator

Shijiazhuang
Heating &
Power

Maxxam Energy

Shaijiazhuang
Thermal Power
Gas Company

ORMAT Air Cooled Bottoming Cycle

1515

Gas Pipeline Compressor Stations


Case History Gas Turbine Exhaust
Gold Creek Project TransCanada Pipeline
RB 211 gas turbine
6.5 MW OEC
1999 start-up
Air cooled
Unattended ( Station manned 5 hours per week)

6.5 MW ORMAT POWER PLANT GOLD CREEK COMPRESSOR STATION TRANSCANADA PIPELINE

1502

Potential Net* Electrical Output from Gas


Turbines Exhaust

1516

ORMAT Energy Converters (OEC)


Typical Applications of Recovered Energy

Application Application Application


1
2
3
Heat Stream
Type

Application
4

Application
5

Application
6

Application
7

Cement Plant
Clinker Cooler

Diesel
Generators

Gas Turbine
Bottoming

Chemical
Plant

Oil
Refinery

Pulp and
Paper Mill

Petrochemical
Plant

Location

Hot
Water

Liquid
Diesel Oil

Flow Rate
(tons/hr)

Condensing
Low Pressure
Steam

Condensing
Hydrocarbons
(Top Vapors)

320

156

13

85

Temperature
Inlet (oC)

95

184

105

Temperature
Outlet (oC)

70

80

80

Exhaust
Gases

Charged
Air

Exhaust Gases

196

203.8

198.5

295

104

275

365

172

463

85

125

110

106

92

Air Cooled
Condensers

Cooling Water:
Flow Rate
(Tons/hr)

750

700

1000

1000

Inlet Temp. oC

10

20

13.5

27

Design Point
Ambient

Outlet Temp. oC

20

30

20

37

Temperature
11oC

OEC Net Output


to Grid - kW

700

1070

930

780

1200

1032

Air Cooled
Condensers
1600
28

Design Point
Ambient

37

Temperature
2oC

2950

5825

Gas Turbine Powered Industrial objectives


POTENTIALLY USERS OF ORC TECHNOLOGY

US Market Potential
Organic Rankine Cycle Bottoming on Gas Turbine Powered
Compressors

Over 1,400 Simple Cycle Gas Turbines in Operation


for gas compression at more than 600 Plants
Nationwide.
10,000,000 Installed Hp Operating at 30% Efficiency.
932 MW of Electrical Generation Potential
189 MCFD of Offset Natural Gas Combustion
11,000 TPD of Offset CO2 Production

PAKISTAN Market Potential


Organic Rankine Cycle Bottoming on Gas Turbine Powered
Compressors

78

Gold Creek ORC Power Plant- 6.5MW on TransAlaska Pipelines Co.

82

83

84

TECHNOLOGY PROVIDERS

85

ORC Equipment Suppliers


Ormat Technologies, Reno, NV Ormat has over 1,000 MW of ORC generation deployed worldwide,
the vast majority of this capacity in geothermal power applications. Ormat recovered energy
generation systems are based on a pre-packaged Ormat Energy Converter (OEC) that consists of a
vaporizer/preheater, turbine generator, air-cooled condenser and feed pump. Ormat participates in
the compressor heat recovery market as an equipment supplier, turn-key EPC, and third party
build/own/operate developer. Currently, Ormat technology is the only ORC equipment installed on
North American compressor stations.
GE Oil and Gas, Houston, TX GE Oil and Gas announced the introduction of the ORegen waste
heat recovery system in January 2009. The ORegen system appears to be designed specifically to
match with GE gas turbines including PGT25, PGT25+, PGT25+G4, MS5001, MS50002C, MS5002D
and MS6001B models. Expected power generation output ranges from 6.9 MW to 15.6 MW across
the gas turbine models. The ORegen ORC system was developed by Nuovo Pignone SpA business
unit, mostly likely using Rotoflow (another GE business unit) expanders. There is no evidence of GE
actively marketing the ORegen system in the United States at this time. The U.S. Department of
Energy announced a research project with GE in December 2008 to optimize the ORC system by
eliminating the secondary heat exchanger loop (i.e., incorporating a direct evaporator design). DOEs
justification of the project indicated that current waste heat recovery technologies, including organic
rankine cycles.are technically feasible but economically unattractive. This limits their current use to
a small number of niche applications. It is unknown if GE has installed any ORegen units in
commercial duty.

86

Turbine Air Systems, Houston, TX. TAS is a designer and manufacturer of preengineered, pre-packaged, modular chilled water and CHP systems. They supply
chiller packages from 200 to 8,000 tons and CHP systems from 1 to 10 MW. TAS is
currently developing a series of pre-engineered, modular waste heat ORC systems
in the 1, 3 and 7 MW size range. TASs initial market focus appears to be
geothermal and industrial waste heat applications, but they are searching for
developer partners to pursue the compressor drive market. The TAS ORC design
has the potential to deliver more power per gas turbine hp than the current Ormat
systems. TAS is working with Ridgewood Power on an initial commercial
demonstration of their technology in an industrial waste heat application.
UTC Power, South Windsor, CT. UTC has commercialized a 250 kW ORC system
named the PureCycle. Market focus has been on geothermal applications
exclusively. The current design is not compatible with the higher temperatures of
gas turbine compressor drives. They have announced plans to develop a 1 MW
system, but status of this development is unknown.
WOW Energies, Houston, TX. WOW is developing the WOWGen ORC power unit.
WOWs unique cascading heat recovery design has the potential for increased
efficiency and power output compared to conventional ORC systems on the market.
Turboden, Italy. Turboden manufactures and sells a broad range of ORC units
ranging in size from 500 kW to 2 MW. They have over 90 systems in operation in
Europe, primarily in biomass recovery systems. They have no systems operating on
reciprocating engines or gas turbines. They do not appear to be active in North
America or in the compressor drive market.
87

Turboden, Italy. Turboden manufactures and sells a broad range of ORC units
ranging in size from 500 kW to 2 MW. They have over 90 systems in operation in
Europe, primarily in biomass recovery systems. They have no systems operating
on reciprocating engines or gas turbines. They do not appear to be active in North
America or in the compressor drive market.
Barber-Nichols, Inc., Arvada, CO. Barber-Nichols is a broad-based
turbomachinery
manufacturer that produces a line of ORC units for waste heat recovery and
geothermal applications. They have commercial units as large as 2 MW producing
geothermal power. They do not appear to be actively pursuing the compressor
heat recovery market at this time.
GMK, Germany. GMK produces modular ORCs in the 0.5 to 5 MW size range for
geothermal and biomass applications. They are developing the INDUCAL unit for
industrial and engine waste heat recovery. There are two INDUCAL units are in
operation at this time.
TransPacific Energy, Carlsbad, CA. TransPacific is developing a multirefrigerant ORC that has the potential for greater efficiency and power output than
commercially available systems. They do not appear to have any systems in
commercial operation.
Infinity Turbine, LLC, Madison WI Infinity markets a 225 kW modular ORC
package. They do not appear to have any systems in commercial operation.
88

Turbo Thermal Corp., Austin, TX Turbo Thermal markets ORC packages in the

Project Developers:
Ormat Technologies- Reno, NV. Ormat serves as a third-party build, own, and
operate developer. Ormat currently owns and operates seven systems on compressor
stations. They also operate an eighth system for a third-party developer, MDU.
NRGreen Power, Albertat, Canada NRGreen Power Limited Partnership, an entity
related to Alliance Pipeline Limited Partnership (Alliance Pipeline), was established in
2002 to pursue the commercial development of electrical generation opportunities
associated with the Alliance Pipeline system. They have four operating systems on
pipeline compressors in Saskatchewan under long-term (20 year) power agreements
with SaskPower. They have plans to construct three additional units on the Alberta
portion of the pipeline.
EnPower Green Energy Generation, Inc., British Columbia, Canada. EnPower is
an independent power producer (IPP) owned by Pristine Power (an independent IPP)
and Enmax Corp (an energy distribution, supply and service company wholly owned
by the City of Calgary).
ICF -They currently have two compressor ORC systems in operation, one under
construction and two under contract and in advanced planning.
Recycled Energy Development (RED), Westmont, IL RED designs, builds and
operates industrial heat recovery power projects. They have no ORC installations or
systems installed on pipeline compressor drives at this time.
Ridgewood Renewable Power, LL- Ridgewood, NJ. Ridgewood is an
owner/operator of renewable energy projects including landfill gas and biomass. They
have expressed interest in pursuing the compressor drive market with ORC
technologies but to date have no installations in place. Ridgewood is working with
89
TAS to on a commercial demonstration of the TAS ORC in an industrial waste
heat

90

91

QUESTIONS?

92

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