GE Power & Water Industrial Waste Heat to Power Solutions Dipti Dash Dipti Dash, Kay Kwok & Fabio Sventurati Presented at: Texas Combined Heat and Power and Waste Heat to Power Annual Conference & Trade Show October 7-8, 2013 Houston, Texas, USA art No of part this of document this document may may be be reproduced, transmitted, stored in in any system in any form, or by any means without the the prior prior written written permission of General of General Electric Electric Company. Compa
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Objective Part 1: Part 2: Part 3: Part 4: Industrial Waste Heat to Power Segments GE ORC Technology - Clean Cycle TM GE ORC Technology - ORegen TM Super Critical CO2 Technology
Dipti Dash Part 1: Industrial Waste Heat to Power (WHP) Segments
WHP market segments New Technology... Heat Recovery Program Focus Conventional GE Technology Geothermal Industrial Solar Engines & Gas Turbines Large GT 100 C 200 C 300 C 400 C 500 C 600 C Advanced Heat Recovery Technologies Conventional Steam Cycles Green, CO 2 free technology 5
Fuel Free Power (MW) GE WHP technology solutions 50 ORC (O&G) ORegen TM Up to 180 MW Steam (P&W) Industrial GT Exhaust 40 Steam (P&W) Aero GT Exhaust 30 ORegen Growth Potential 20 10 ORC (P&W) Clean Cycle 100 200 300 400 500 600 Waste Heat Temp. (Deg C) 700 Geothermal Steel Mill Refinery Cement Broad applications with wide temperature range ORC Organic Rankine Cycle O&G GE Oil & Gas division P&W GE Power & Water division 6
Kay Kwok Part 2: The Clean Cycle Heat to Power Generator
Clean Cycle heat to power generators Recip engines Turbines Biomass boilers HEAT POWER Heat source Heat energy is captured from exhaust streams Requires >800kWth at >300 F Example: 1.5MW recip engine Clean Cycle generator One unit generates ~100kW Modular, re-deployable More heat? Stack multiple units No fuel, no emissions Electricity Distributed, base-load; 90%CF Power factor of 1 matches grid Sold to grid for revenue, or used on-site 8
Why heat to power Industrial Efficiency 20 to 50% of industrial energy input is lost as waste heat. 1 The U.S. industrial sector accounts for about 1/3 of the total energy consumed in the United States 1 Power plant efficiency The global average efficiency of power plants that generate only electricity is 41%. Almost 3/5 of the primary energy used in these plants becomes waste heat, of no economic value. 2 Why Organic Rankine Cycle? About 60% of waste heat losses are at temperatures below 450 F [230 C]. 1 Sources: 1 2008 DOE report: Waste Heat Recovery: Technology and Opportunities in US industry 2 International Energy Agency, World Energy Outlook 2012 9
How the Clean Cycle works Closed circuit hot water loop delivers heat energy and allows access to a wide range of heat temps Cooling is typically achieved by a water or air cooled condenser Power produced is grid quality due to built in power electronics and inverter power 277 F IPM 156 F Water loop ~300 F Clean Cycle II cooling Exhaust heat >300 F 98 F 95 F 10
Savings or Revenue / yr Benefits of 100kW of fuel free power Savings or revenue Electricity can be sold to the grid or used on-site to offset local consumption $300,000 Savings or revenue from 100kW ORC ($/yr) No added fuel Heat is the only input required for the Clean Cycle unit to generate electricity $250,000 $200,000 No added emissions The energy conversion process is closed loop and involves no combustion $150,000 $100,000 Reliable electricity Non-invasive to heat source & requires no major overhauls, no lubricants, and no operators $50,000 Proven performance Same basic unit is deployed regardless of heat source *Assumes diesel engine fuel efficiency of 0.25L/kWh and 8,000 operating hours $- $/kwh Assumptions: 100kW at 8,000 operating hours per year 11
Components of an installation Example: reciprocating engine heat KEY Existing plant Clean Cycle & modular components Heat source Focus: recip engines, boilers, turbines >1MW Heat Capture Exhaust gas heat exchanger & damper Heat Transfer Controls water loop that delivers heat to the Clean Cycle Clean Cycle Converts heat into power Heat Rejection Cooling system used to condense the cycle s working fluid 12
Differentiators Reliability Turbine generator floats on non-contact magnetic bearings No gearbox, no external seals, no lubrication required to operate Integrated Power Module Modular, package approach Goal is for installations to be like a Lego set: Install = Clean Cycle package + HPHW loop + heat source Proven fleet in operation Accumulated over 200,000 operating hours >120 units shipped Italy USA UK Romania Czech Rep Germany 13
Fabio Sventurati Part 3: GE ORegen TM
ORegen TM ORegenTM is GE Organic Rankine Cycle System designed to recover waste heat energy from GT or similar waste heat sources water and CO2 free Developed for power gen application Mechanical drive application also possible References #1 17MW system sold in Canada on a pipeline station delivered in December 2012 COD Fall 2013 #3 17MW systems sold in China on 3 pipeline stations - delivery in March 2015 COD August 2015 #1 17MW system sold in Brunei on a powergen station delivery in December 2014 COD June 2015 #1 17MW system sold in Thailand on a pipeline station delivery in February 2015 COD Summer 2015 15
Waste heat Why waste heat recovery? Waste heat GT simple cycle efficiency: 25 40% O&G GT mainly in simple cycle Global trends: CO2 emission reduction Increase efficiency Increase in power demand Air Fuel Simple cycle GT Gas Turbine Exhaust Gas ORegen T M Electricity production sell back to grid Help comply with CO2-related regulations Increase plant efficiency + = Up to 17MW of power recovery 77% of Oil and Gas installed Gas Turbines are in simple cycle 16 No part of this document may be reproduced, * ORegen transmitted, is a trademark stored in any of Nuovo system Pignone in any form, Spa or and by any is available means without in selected the prior markets written permission of General Electric Company.
Temperature [ C] The ORC concept The Organic Rankine Cycle is a thermodynamic cycle based on the Rankine classic cycle using an organic working fluid GE selected cyclo-pentane as working fluid ORC cycle T-S diagram 250 200 150 T dew T bubble T cycle @ min p T cycle @ max p Heaters Expander Recuperator Condenser Pump Pre-heater Super-heater Vaporize r Expansion Working fluid selection by GRC Munich Cyclo-pentane main characteristic Boiling point: 121 F (49.3 C) Freezing point: -137 F (-94 C) Molecular Weight: 70.1 Appearance: clear, colorless liquid No corrosion issue on plant equipment 100 Regenerator Regenerator Condenser Pump 50-3 -2.5-2 -1.5-1 Entropy [kj/(kg C)] 17
ORegen TM plant schematic & scope of supply PGT25+ case study overall plant efficiency up to 51% Gas Turbine Exhaust OIL HEATER Diathermic Oil loop The basic scope of supply for a typical conversion includes the following: Organic Fluid C5H10 system Diatermic oil system Vaporizer & heat exchangers Turboexpander genset Condenser C5 and oil pumps Hot Oil Pump HEAT EXCHANGERS Cyclopentane loop Expander Generator RECUPERATOR Fan C5 Pump CONDENSER 18
Turboexpander (5-17 MW family) 16-blade wheels (17-4PH) 19
ORegen Typical Layout Diverter only interface with GT GT exhaust stack with ORegen installed Waste Heat Oil Heater GT exhaust stack Diathermal Oil piping Turbo-Expander Control cab C5 condenser Cyclo-pentane island 20
ORegen TM configurations Direct Parallel Oil GT#1 WHRU ORC Condenser GT#1 WHRU #1 ORC Condenser GT#n WHRU n Multi cycles Parallel Gas GT#1 WHRU ORC#1 ORC#2 Condenser #1 Condenser #2 GT#1 - - - - - - GT#n WHRU ORC Condenser To be defined as typical arrangement To be scaled up / down from a standard design. To be selected case by case. depending from the site conditions and project requirements 21
ORegenTM output in direct configuration GT Model GT Power (KW) Exhaust Flow (Kg/sec) Exhaust Temp ( C) GT Efficiency (%) ORC Output (MWe) System Efficiency PGT25 (*) 23 261 68.9 525 37.7% 6.9 48.9% PGT25+ (*) 31 364 84.3 500 41.1% 7.9 51.5% PGT25+ G4 (*) 33 973 89.0 510 41.1% 8.6 51.5% MS5001 (*) 26 830 125.2 483 28.4% 11.3 40.4% MS5002B (*) 26 100 121.6 491 28.8% 10.8 40.7% MS5002C (*) 28 340 124.3 517 28.8% 12.4 41.4% MS5002D (*) 32 580 141.4 509 29.4% 13.8 41.9% MS6001B (*) 43 530 145.0 544 33.3% 15.6 45.2% LM6000 (**) 43 397 125.6 454 41.7% 9.7 51.1% (%) Reference data @ISO Conditions. 100% GT Turbine load (*) Values at gas turbine shaft (**) Values at generator terminals for LM6000PC coupled to 60 Hz generator 22
ORegen plant key cycle features Designed for Unmanned operation No need of certified people to be 24h available at site Turndown capabilities Best solution for GT partial load operation @50% GT load still 80% of power recovered Highly reliable gas Expander as main unit No blow down Negligible organic fluid consumption No water requirement No water system treatment required Efficiency Up to 13 points C5 Bottom pressure Above atmospheric pressure, High Safety (No O 2 ingestion) C5 Top pressure Below fluid critical pressure (No supercritical operation), Best Power Recovery Thermal Oil Great operability Range 35... +330 C Condenser sized to handle uncondensable Compact footprint, C5 condensing above atmosphere Specific CO2 Decrease by 40% Decrease CO 2 specific emissions and generate up to 17 MWe 23
Efficiency improvement 20% CO 2 footprint 20% Carbon credits singular enabler Cyclo-pentane as working fluid in a closed loop no water! ORegen TM Produce up to 17MW electric power with no additional fuel by recovering heat from GT exhaust 24 GE Proprietary Information 24 GE Confidential GE 2011 & Proprietary All Rights Information Reserved GE 2012 All Rights Reserved
Part 4: Dipti Dash Super Critical CO 2 Alternative Bottoming Cycle Evolution
Why Supercritical CO2? Constant Pinch for SCO2 Advantages of CO2 as working fluid Low critical pressure & temperature Non-flammable, non-toxic, non-corrosive, thermally stable High density enables compact system Easily available and Inexpensive 26
Simple CO2 Rankine cycle Uniqueness of CO 2 High thermal stability Non-flammable May Condense for pumping Small footprint Low carbon footprint Similar configuration to typical ORC 22-25% first-law efficiency Approx. 1/3 of exhaust exergy left behind in exhaust stream Generator ~350 C 80 bar ~500 C Recup 1 1 GT exhaust heat 550 C ~300 C 250 bar Heater 350 C 250 bar Condenser 80 bar 27 Poor efficiency on fuel-lhv basis
Cycle layouts for heat recovery Simple sco2 cycle GE Proprietary Design: Two, cascaded sco 2 loops for better source utilization 28
GE advanced CO2 WHR cycle Low-pressure stream GT Exhaust 500 C System features: Non flammable working fluid higher efficiencies than ORCs No need for intermediate loop Compact turbo machinery Generator High-pressure stream A B Heater 150 C Mid-T Recup Lo-T Recup Compressor/ Pump Cooler/Condenser 30% first-law efficiency Better utilization of exhaust energy 10% more power output compared to ORC Compact turbo-machinery with low footprint 29
Reheat CO2 vs Steam Rankine Cycle Reheat CO2 (A Case Study with 2XLM6000 CC) Steam Net Power : 137.5 MW Efficiency : 49.31 % Plant Cost (10 th unit) : MM$ 146.6 No DM Water Plant, less O&M More suitable for remote operation & fast start Smaller foot print with once through cooling system Net Power : 140.38 MW Efficiency : 50.35 % Plant Cost : MM$ 139.5 Matured technology More efficient at high ambient Reheat CO2 to cost MM13$ less to match Steam on LCOE basis*. Scope for further plant optimization and cost reduction through Expander, Feed Pump & ACC * Fuel at $5/mmBtu 30
For more GE capabilities see GER 3430G at http://site.ge-energy.com/prod_serv/products/tech_docs/en/downloads/ger3430g.pdf Contact your local GE Sales Application Engineer for help