Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Thermo-electricity
Thermo-acoustics
Stirling Engines
Fuel Cells
INDUSTRIAL HEAT
RECOVERY
Why & How
INTERNATIONAL CHAMBER OF
COMMERCE
Details on:
GOVERNMENTAL SUPPORT
BETTER COMMUNICATION
PAKISTAN ENERGETIC
SITUATION
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
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
AGRICULTURE
15-20
PAPER
15-25
GLASS / CERAMIC
20-25
COMMERCIAL BUILDING
10-25
10-30
TEXTILE
14-30
FERTILIZER
16-30
CEMENT
20-40
IRON / STEEL
23
PETROCHEMICAL
35
DOMESTIC
PUBLIC UTILITY SERVICES
10-15
10
Installed
Capacity
(MW)
Expected
COD
IPP
227
Jun. 2010
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
Public
425
Dec. 2010
IPP
225
Dec. 2010
Western ElectricProject
IPP
150
Dec. 2010
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
Capacity
Added in
each Year
(MW)
Total
Installed
Capacity
(MW)
4856
26965
20
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.
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
Source: www.heat2power.com
29
System 1
System 2
System 3
System 4
System 5
10
25
40
$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
$539.95
$653.68
$828.00
$1,094.79
$1,319.06
$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
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
ORC Technology
32
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36
37
38
39
40
41
http://www.acore.org/files/publications/ACORE_USonly_Q_REVIEW_low4.pdf
42
43
44
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
module:
electric output:
570 kWel
46
47
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ORC Technology
Refrigerant properties
List of Providers
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Heat Sources
Industrial and Process Plants
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
1515
6.5 MW ORMAT POWER PLANT GOLD CREEK COMPRESSOR STATION TRANSCANADA PIPELINE
1502
1516
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
700
1070
930
780
1200
1032
Air Cooled
Condensers
1600
28
Design Point
Ambient
37
Temperature
2oC
2950
5825
US Market Potential
Organic Rankine Cycle Bottoming on Gas Turbine Powered
Compressors
78
82
83
84
TECHNOLOGY PROVIDERS
85
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