(PDF) Stationary/Transportation Heat-to-Power Applications with CN300 ORC Technology

STATIONARY/TRANSPORTATION

HEAT-TO-POWER APPLICATIONS

WITH CN300 ORC TECHNOLOGY

ASME Turbo Expo 2014

Exhibitor Presentation Stage

CCD Congress Center | Düsseldorf, Germany

Keith D. Patch

ORC Product Manager

Concepts NREC (CN )

+1 (781) 937- 4616

kpatch@conceptsnrec.com

Tuesday, June 17, 2014, 3:15 PM CET

2

Copyright Statement

The material in this presentation is covered by various copyrights, including

transcribed, stored in a retrieval system, or translated into any language or

computer language, in any form or by any means—electronic, mechanical,

magnetic, optical, chemical, manual or otherwise—without prior written

permission from Concepts ETI, Inc., 217 Billings Farm Road, White River Jct.,

Vermont 05001, USA. Portions of this volume may require permissions of

individuals associated with organizations other than Concepts ETI, Inc.

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Introduce presenter and company

Organic Rankine Cycle (ORC) background

and history

Heat-to-power applications

Stationary applications

Transportation applications

CN300 ORC turbogenerator product/benefits

Initial 300 kWe product from Concepts NREC (CN)

Low capital cost; minimizes O&M costs

Customized aero design to match site requirements

Custom designs ensure maximum system efficiency

Presentation Overview

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CN is a ≈50 year-old company,

with ≈100 employees

72 patents granted, 19 patents pending

39 employees have advanced college

degrees

ORC engineering experience: from the

early 1970s to the present time

Keith D. Patch is a 25+ year veteran

of the energy field

Waste heat recovery, fossil fuels,

biomass, fuel cells, lithium-ion

batteries, and nuclear instrumentation

Residential-, commercial-, industrial-,

and utility-scale

Introduction

Typical CFD Turbine Analysis Results

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Market Opportunity of the

Waste Heat Problem

28% of the World’s Total

Energy Use Is Wasted but Is

Potentially Recoverable

Productive Utility/

Industrial Energy Use

Can recover 144 GWe of power: US$359B (at US$2,500/kWe)

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World geothermal potential is 148 GWe

World biomass potential is 25 GWe

World solar thermal potential is 25 GWe

Natural energy + waste heat markets: 342 GWe or $854B

The World’s Natural Energy Market

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Thomas Howard, alcohol/ether engine, 1826

Du Tremblay engine, France, 1850–56

Ether ORC for marine steam engine

Frank W. Ofeldt, U.S. Patent 279,270, 1883

Naphtha ORC engine for marine power

NREC founded, 1956; Concepts ETI, Inc.

founded, 1980

1st modern ORC prototype, Harry Zvi Tabor

and Lucien Bronicki, 1961

1st commercial ORC sale, Ormat, 1972

CN staff active in ORC development, 1970s–1980s

CN CN300 ORC development, began in 2011

ORC Development Timeline

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Simple ORC System

Evaporator

Heat Turbine/Generator

Electricity

Pump

Condenser

Rejected Heat

An ORC is best suited for making electricity from low-

grade heat sources, using an organic fluid to match the

fluid’s properties with the temperature of the heat source

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Above 50 MWe: steam Rankine cycle is the clear choice

For primary power generation

For high-temperature waste heat

Although a 95 MWe geothermal ORC plant (2013) exists

Below 5 MWe: ORC is the clear choice

For primary power generation

For low-, medium-, or high-temperature waste heat

Eliminate cost of steam boiler plant operators

Eliminate cost of water, water treatment system, chemicals,

deaerator, etc.

Why Use the ORC Instead

of the Steam Rankine Cycle?

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28% of the world’s total energy use is wasted but is

potentially recoverable

ORC natural energy market + waste heat equipment

market is 342 GWe or $854B

ORC system efficiencies are 10–25%

ORC systems are preferred over steam Rankine

cycle systems for most sub-5,000 kWe heat-to-

power applications

ORC systems are the only heat-to-power solution

for low-temperature applications

Summary of ORC

Background and History

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Stationary applications

Large worldwide installed base

Often sized over 100 kWe

•World’s largest ORC = 95 MWe unit

Typical uses include:

•Geothermal power

•Reciprocating engine bottoming cycle

Transportation applications

Representative ORC demonstration units

•Earliest demo: U.S. DOE-funded 36 BHP

demo in the 1970s–1980s (photo at right)

•Current DOE SuperTruck program

Commercial products not yet available

Heat-to-Power Applications

Patent

Pending

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Natural sources

Geothermal

Biomass

Solar thermal

Waste heat recovery

Waste treatment plants/

incinerators

Power generation exhaust

Glass and cement industry

Oil and gas industry

Chemical industry

Steel industry

Pulp and paper industry

Typical Stationary ORC Applications

Cumulative Worldwide

ORC Installations

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Truck OEMs must

meet stringent fuel

economy standards

ORC fuel economy

improvement goal of ~6%

Two-stage ORC turbine

has better performance,

but is too complicated

Down-selected to a

single-stage axial turbine

Turbine designed/built/

validated in on-road testing

ORC Design for Heavy Truck Engine –

CN/Cummins/U.S. DOE (SuperTruck)

Photo by Sarah Gerrity, Energy Department

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CN Has the Solution to

Expand the Clean Energy Market

Market Solution Problem

60% of the world’s

primary energy is

lost as waste heat

CN300–CN5000:

reliable, low-

total-cost devices

High capital expense

and high maintenance

cost of existing waste

heat-to-power systems

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Commercial Product – CN300

Flow

Out

Flow

In

Features

Hermetically-sealed design

Modular turbine cartridge

Magnetic bearings (oil-free)

Advantages

Simplicity – eliminates all

seals, gears, couplings,

lube oil system, and oil

contamination

Reduced capital and

O&M costs

Reduced footprint

Increased reliability

Optimized performance

Wide working fluid flexibility

Output from 150 to 330 kWe

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Competitive Advantages of the CN300

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CN300 Specifications

Initial member of CN’s ORC Turbine Generator Unit (TGU) product line

Designed using CN’s Agile Engineering Design System®

Gross power range

150–330 kWe

TGU speed

20,000 rpm

Turbine inlet temperature range

180–425°F (80–220°C)

Turbine casing inlet pressure rating

700 psig [49 Bar (Absolute)]

Turbine casing outlet pressure rating

200 psig [14 Bar (Absolute)]

Turbine pressure ratio range

2:1–25:1

Working fluid compatibility

R112, R113, R114, R134a, R236fa, R245fa

TGU size

42 in. x 24 in. x 34 in. (1.07 m x 0.62 m x 0.87 m)

1200 pounds (544 kg)

Electrical details

400–480 VAC, 3-phase, 50–60 Hz Agile Engineering Design System is a registered trademark of Concepts ETI, Inc.

Mach Number Contours

Through Flow Path

Flow Path

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ORC heat-to-power systems are an established clean

energy technology

ORC heat-to-power systems can efficiently convert

renewable thermal energy and waste heat to

electricity

Widespread stationary and transportation ORC

applications exist

Recent advancements have improved ORC reliability

and virtually eliminated maintenance

The CN300 provides best-in-class first cost, operating

and maintenance costs, efficiency, and flexibility for

converting heat to ≈300 kWe of electrical power

Summary

Stationary/Transportation Heat-to-Power Applications with CN300 ORC Technology

Abstract

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