Thomas Frey - Organic Rankie Cycles Waste Heat Recovery PDF

Organic Rankine Cycles for
Waste Heat Recovery

NASA/C3P - 2009 INTERNATIONAL WORKSHOP
ON ENVIRONMENT AND ALTERNATIVE ENERGY
“Global Collaboration in Environmental and

Alternative Energy Strategies”
11. November 2009
Dr. Thomas Frey

GE Global Research Center Munich (GRC)
Waste Heat Recovery
Overview
What is Waste Heat Recovery (WHR)?
Benefits
Heat Source
• CO2-free additional power
• Increased plant / process efficiency Qin
• Fuel savings
Driving forces WHR System
• Fuel, electricity prices / incentives Power
• CO2 or emissions constraints Qout
• Grid independence
Heat Sink
Key CTQ: CAPEX ($/kW)
Capturing low grade heat sources for energy production
3/
Waste Heat Recovery /
Copyright  2009 General Electric 12/7/2009
Waste Heat Recovery 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
Geothermal & Solar Industrial Waste Heat

• 100 GW geothermal potential (MIT)* • Approx. 950 PJ heat losses (100-200°C)*
• 200 GW solar potential* • $6 B/yr energy wastes*
• Refineries, cement, pulp & paper, …
Reciprocating Engines
• Approx. 5% pts efficiency boost Gas Turbines
• Reduced fuel consumption & emissions • WHR adds up to 20% power
(* US only)
Green, CO2 free technology

4/
Waste Heat Recovery
Organic Rankine Cycle (ORC)
Organic Rankine Cycle
Heat
Source
Cycle Principle BOILER
• Expansion of organic fluid Near-

Pressurised saturated
Features liquid
ORC vapour
• Robust, simple system Shaft

Fan Power Work
• Mature, well known components
• Only low temperatures required Pump
CONDENSER
Power
• On-site operators not required
Technology Status
• Conventional ORCs successfully in operation for many years
• CAPEX: ~ 2000 – 6000 $/kW, f (kW, temp, site etc.)
Advantaged technology for small and low T applications
6/
ORC Efficiency
Th
Carnot efficiency Carnot efficiency: ηC = 1 −
Tc
• Theoretical maximum
• Increases with increasing ∆T Tc=20°C Tc=40°C
Real efficiency 60
• Process always has losses 50
Carnot efficiency / %
• 30 – 50% of Carnot 40
30
Potential improvements
• Reduce losses 20
• Increase max. temperature 10
(risk: fluid decomposition) 0

50 100 150 200 250 300 350 400
• Optimize cold cycle end Temperature of heat source Th / °C
(increased cost)
7/
Waste Heat Recovery
Example: ORC for Reciprocating
Engines
Gas Engine Heat Sources
1415 kW
Mechanical power 540 kW electrical
power
Fuel MW
3,4 MW Exhaust Gas
Exhaust
Inter Cooler
Intercooler
600 kW @ 472 (180)°C

J 420 GS-A25 Water
Jacket Water
Oil
Oil
Biogas
218 kW @ 160°C
160 kW @ 90°C
432 kW @ 95°C
Challenges for waste heat recovery
• Use which sources? ~810 kW ~600 kW
~95°C ~472°C
• High specific cost due to low power LT heat HT heat
• Thermal integration into engine
Two heat sources with different temperature level

9/
Example: GE Jenbacher Recips WHR
Reciprocating Containerised
engine ORC
“Medium” “Large”
Engine power 1 – 1,5 MW 3 MW
Specifications
Fuel Biogas, landfill, NG Natural Gas

ORC power boost 110 - 140 kW 300 - 370 kW
Efficiency increase > 4% pts > 5% pts
ORC: Bottoming cycle for reciprocating engines

10 /
GRC Waste Heat Recovery Focus
Reciprocating Engines Industrial Gas Turbines
• Customer prototype installation Q1/2010 • GE O&G ORegenTM cycle developed

• Approx. 5% pts efficiency boost • ORC adds approx. 20% power to GT
• Potential for 50%+ efficient engine • Ecomagination certified
Real Fluid Cycle

T
Vapor dome
Ideal
(trilateral)
Industrial Waste Heat Real Discovery

s
• Collaboration with industry (e.g. • Development of high efficient cycles

utilities, cement, refineries etc.) • New fluids identification
• Identification of new WHR • CAPEX optimized components
opportunities & markets
• Simulation & experiments
Key to low $/kW: New cycles & integration into heat source
11 /
Thank you.
Acknowledgement:
Project is partly funded by the Bavarian Ministry for
Economy, Infrastructure, Traffic and Technology
12 /

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Organic Rankine Cycles for

Waste Heat Recovery

“Global Collaboration in Environmental and

11. November 2009

Dr. Thomas Frey

• Fuel, electricity prices / incentives Power

• CO2 or emissions constraints Qout

Capturing low grade heat sources for energy production

Geothermal Industrial Solar Engines & Gas Turbines Large GT

Advanced Heat Recovery Technologies

Conventional Steam Cycles

Geothermal & Solar Industrial Waste Heat

Green, CO2 free technology

Cycle Principle BOILER

• Expansion of organic fluid Near-

• Robust, simple system Shaft

Advantaged technology for small and low T applications

• Process always has losses 50

• Increase max. temperature 10

(risk: fluid decomposition) 0

600 kW @ 472 (180)°C

Two heat sources with different temperature level

Fuel Biogas, landfill, NG Natural Gas

ORC: Bottoming cycle for reciprocating engines

• Customer prototype installation Q1/2010 • GE O&G ORegenTM cycle developed

Real Fluid Cycle

Industrial Waste Heat Real Discovery

• Collaboration with industry (e.g. • Development of high efficient cycles

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