An Approach to Heat Recovery in Rural Alaska Introduction Introduction Background – Maintenance & Repair Background – Maintenance & Repair Small Scale:

An Approach to Heat RecoveryAn Approach to Heat Recovery in Rural Alaska in Rural Alaska

IntroductionIntroduction Background – Maintenance & RepairBackground – Maintenance & Repair Small Scale: 50 kW to 3500 kWSmall Scale: 50 kW to 3500 kW Heat Recovery: Heat Recovery: SAVES Fuel - NOT Primary SAVES Fuel - NOT Primary

HeatHeat

Keep it SIMPLEKeep it SIMPLE

Rules of ThumbRules of Thumb

1/3 Electricity : 1/3 Jacket Water : 1/3 Exhaust1/3 Electricity : 1/3 Jacket Water : 1/3 Exhaust 2000 BTU/kW-Hr (jacket water)2000 BTU/kW-Hr (jacket water) 100,000 BTU delivered Heat = 1 gallon #1 Diesel100,000 BTU delivered Heat = 1 gallon #1 Diesel 0.3 x Power Plant Annual Fuel Use x 0.60.3 x Power Plant Annual Fuel Use x 0.6 Pumping Energy Costs <= 10% Fuel ValuePumping Energy Costs <= 10% Fuel Value Size System Flow for 2/3rds Peak LoadSize System Flow for 2/3rds Peak Load

End-UsersEnd-Users

Water Plant / WasheteriaWater Plant / Washeteria SchoolsSchools Public Facilities (Clinics, City Offices, Rec Public Facilities (Clinics, City Offices, Rec

Centers)Centers) Ice / Cold Storage (low temp absorption chiller)Ice / Cold Storage (low temp absorption chiller)

Design ConsiderationsDesign Considerations

Power Plant Diesels (heat rejection, pump capacity)Power Plant Diesels (heat rejection, pump capacity)– No In-Line Booster PumpsNo In-Line Booster Pumps– Secondary Pumped LoopSecondary Pumped Loop– Power Generation = Primary Power Generation = Primary 

End-User Heat LoadsEnd-User Heat Loads– Historical Fuel Use BasedHistorical Fuel Use Based

– HDD and Composite UA HDD and Composite UA

Design Considerations cont’dDesign Considerations cont’d

PumpingPumping– Minimize Pumping Energy (valves/restrictions)Minimize Pumping Energy (valves/restrictions)– RedundancyRedundancy

Arctic PipingArctic Piping– Welded steel, HDPE jacketedWelded steel, HDPE jacketed– Copper where indoors/utilidorsCopper where indoors/utilidors

InstrumentationInstrumentation– Thermometers (thermo-wells)Thermometers (thermo-wells)– Pressure Gauges (isolation valves)Pressure Gauges (isolation valves)– Air Vents (minimize + isolation valves)Air Vents (minimize + isolation valves)

Design Considerations – cont’dDesign Considerations – cont’d

Air ControlAir Control– Air Eliminator (rol-air-trol vs. air scoop)Air Eliminator (rol-air-trol vs. air scoop)– Expansion Tank Sizing (40F or –40F)Expansion Tank Sizing (40F or –40F)

Pre-charge (set for specific application) Pre-charge (set for specific application) 

Arctic Piping Loop FluidArctic Piping Loop Fluid– Ethylene / Propylene / Water Ethylene / Propylene / Water 

MAINTAINABILITY / ACCESSMAINTAINABILITY / ACCESS– Equipment LocationEquipment Location– ValvingValving

End-User ConnectionsEnd-User Connections

Direct ConnectionDirect Connection Full Boiler Flow thru Heat ExchangerFull Boiler Flow thru Heat Exchanger

– Heat Availability close to Boiler CapacityHeat Availability close to Boiler Capacity Partial Boiler Flow thru Heat ExchangerPartial Boiler Flow thru Heat Exchanger

– Heat Availability << than Boiler CapacityHeat Availability << than Boiler Capacity

EquipmentEquipment

Heat ExchangersHeat Exchangers– P&F Clip on Gaskets (>70 gpm)P&F Clip on Gaskets (>70 gpm)– Brazed Plate (<70 gpm)Brazed Plate (<70 gpm)

ValvesValves– Lug Style ButterflyLug Style Butterfly– Full Port Ball ValvesFull Port Ball Valves

(no gate valves)(no gate valves)

Arctic PipingArctic Piping– Preinsulated Arctic Pipe PackagePreinsulated Arctic Pipe Package

Daily OperationsDaily Operations

Daily LogDaily Log– Monitor and Record Monitor and Record

Temperatures, Pressures, Pump OperationTemperatures, Pressures, Pump Operation

– Check Glycol Concentration & InhibitorsCheck Glycol Concentration & Inhibitors

Typical Jacket Water Heat Rejection Typical Jacket Water Heat Rejection of Dieselsof Diesels

Manufacturer Model RPM Eng HPElec Out

(kW)J. W. Heat

(BTU/kW-Hr)J.W. Heat (BTU/Hr)

Caterpillar 3508 1200 617 430 1975 849,250Caterpillar 3508 1200 792 560 1965 1,100,400Caterpillar 3512 1200 940 665 2130 1,416,450Caterpillar 3512 1200 1206 855 2135 1,825,425Cummins LTA10 1200 165 115 2140 246,100Cummins LTA10 1800 250 175 2010 351,750Cummins KTA19 1200 410 285 1960 558,600Cummins KTA19 1800 600 415 2240 929,600Cummins KTA38 1200 825 575 2240 1,288,000Cummins KTA38 1800 1200 835 2240 1,870,400John Deere 6068TF 1800 135 90 2125 191,250John Deere 6081TF 1800 190 125 2245 280,625

Typical Jacket Water Heat Rejection Typical Jacket Water Heat Rejection of Diesels (continued)of Diesels (continued)

Manufacturer Model RPM Eng HPElec Out

(kW)J. W. Heat

(BTU/kW-Hr)J.W. Heat (BTU/Hr)

Detroit Diesel Series 60 1800 490 314 2180 684,520Jacket Water 314 1360 427,040After Cooler 314 820 257,480

Caterpillar 3456 1800 764 500 2197 1,098,500Jacket Water 500 1330 665,000After Cooler 500 867 433,500

Caterpillar D353 1200 448 310 3350 1,038,500(300 series of Cat Diesels are Pre-Combustion Chamber Engines)

Caterpillar 3508 1200 792 560 3250 1,820,000(marine jacketed diesel)

6-Port P&F Heat Exchanger6-Port P&F Heat Exchanger

Wood Boiler & Heat ExchangerWood Boiler & Heat Exchanger

Electric Boiler & Heat ExchangerElectric Boiler & Heat Exchanger

Inaccessible Heat ExchangerInaccessible Heat Exchanger

Inaccessible Heat ExchangerInaccessible Heat Exchanger

AVEC Ambler PlantAVEC Ambler Plant

AVEC Kiana HRMAVEC Kiana HRM

AVEC Kiana HRM-radiatorsAVEC Kiana HRM-radiators

AVEC Anvik Heat RecoveryAVEC Anvik Heat Recovery

AVEC Anvik Heat ExchangerAVEC Anvik Heat Exchanger

IASD Anvik Heat Recovery ModuleIASD Anvik Heat Recovery Module

IASD Anvik Heat ExchangerIASD Anvik Heat Exchanger

Selawik Power ModuleSelawik Power Module

Heat Exchanger & BF-ValveHeat Exchanger & BF-Valve

Secondary Pumped Loop HXRSecondary Pumped Loop HXR

AMOT TreeAMOT Tree

AVEC SelawikAVEC SelawikHRM-beforeHRM-before

AVEC SelawikAVEC SelawikHRM-New StyleHRM-New Style