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Organic Rankine Cycles forWaste Heat Recovery
NASA/C3P - 2009 INTERNATIONAL WORKSHOPON ENVIRONMENT AND ALTERNATIVE ENERGY
Global Collaboration in Environmental and
Alternative Energy Strategies
11. November 2009
Dr. Thomas FreyGE Global Research Center Munich (GRC)
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Waste Heat RecoveryOverview
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What is Waste Heat Recovery (WHR)?
Benefits
CO2-free additional power
Increased plant / process efficiency
Fuel savings
Driving forces
Fuel, electricity prices / incentives CO2 or emissions constraints
Grid independence
Key CTQ: CAPEX ($/kW)
Heat Source
Heat Sink
WHR System
Qin
Qout
Power
Capturing low grade heat sources for energy production
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Waste Heat Recovery Segments
Reciprocating Engines
Approx. 5% pts efficiency boost
Reduced fuel consumption & emissions
Geothermal & Solar
100 GW geothermal potential (MIT)*
200 GW solar potential*
Industrial Waste Heat
Approx. 950 PJ heat losses (100-200C)*
$6 B/yr energy wastes*
Refineries, cement, pulp & paper,
Green, CO2 free technology
WHR adds up to 20% power
Gas Turbines
Engines & Gas TurbinesGeothermal
ConventionalGE Technology
New Technology ... Heat Recovery Program Focus
100C 200C 400C 500C 600C
Conventional Steam Cycles
Advanced Heat Recovery Technologies
300C
Industrial Large GTSolar
(* US only)
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Waste Heat RecoveryOrganic Rankine Cycle (ORC)
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Organic Rankine Cycle
Cycle Principle
Expansion of organic fluid
Features
Robust, simple system
Mature, well known components
Only low temperatures required On-site operators not required
Technology Status
Conventional ORCs successfully in operation for many years
CAPEX: ~ 2000 6000 $/kW, f (kW, temp, site etc.)
BOILER
CONDENSER
HeatSource
Near-
saturatedvapour
Fan Power
PumpPower
ORC
Pressurisedliquid
Shaft
Work
Advantaged technology for small and low T applications
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0
10
20
30
40
50
60
50 100 150 200 250 300 350 400
Temperature of heat source Th / C
Carnotefficiency/%
Tc=20C Tc=40C
ORC Efficiency
Carnot efficiency
Theoretical maximum
Increases with increasing T
Real efficiency
Process always has losses
30 50% of Carnot
Potential improvements
Reduce losses
Increase max. temperature
(risk: fluid decomposition) Optimize cold cycle end
(increased cost)
Carnot efficiency:c
h
CT
T=1
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Waste Heat RecoveryExample: ORC for ReciprocatingEngines
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Gas Engine Heat Sources
Challenges for waste heat recovery
Use which sources?
High specific cost due to low power
Thermal integration into engine
MWMW
OilOil
Jacket WaterJacket Water
Inter CoolerInter Cooler
Exhaust GasExhaust Gas
Mechanical power 540 kW
Fuel
1415 kWelectricalpower
~810 kW~95C
LT heat
~600 kW~472CHT heat
Exhaust
Intercooler
Water
Oil
3,4 MW
600kW@47
2(180)C
218kW
@160C
432kW
@95C
160kW
@90C
Two heat sources with different temperature level
J 420 GS-A25Biogas
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Example: GE Jenbacher Recips WHR
Specifications
Natural GasBiogas, landfill, NGFuel
> 5% pts> 4% ptsEfficiency increase
300 - 370 kW110 - 140 kWORC power boost
3 MW1 1,5 MWEngine power
Medium Large
ORC: Bottoming cycle for reciprocating engines
Containerised
ORC
Reciprocating
engine
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GRC Waste Heat Recovery Focus
Industrial Gas Turbines
GE O&G ORegenTM cycle developed
ORC adds approx. 20% power to GT Ecomagination certified
Reciprocating Engines
Customer prototype installation Q1/2010
Approx. 5% pts efficiency boost Potential for 50%+ efficient engine
Discoverys
T
Real Fluid Cycle
Real
Ideal(trilateral)
Vapor dome
s
T
Real Fluid Cycle
Real
Ideal(trilateral)
Vapor dome
Development of high efficient cycles
New fluids identification
CAPEX optimized components
Simulation & experiments
Industrial Waste Heat
Collaboration with industry (e.g.utilities, cement, refineries etc.)
Identification of new WHR
opportunities & markets
Key to low $/kW: New cycles & integration into heat source
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Thank you.
Acknowledgement:Project is partly funded by the Bavarian Ministry forEconomy, Infrastructure, Traffic and Technology
