Organic Rankine Cycle Technology

Organic Rankine CycleTechnologyOctober 2010

UNITED TECHNOLOGIES CORPORATIONHamilton Sundstrand Pratt & Whitney SikorskyOtis UTC Fire & Security UTC Power Carrier

PRATT & WHITNEY OVERVIEWLarge EnginesSmall EnginesAftermarketServicesSpace PropulsionPower SystemsMilitary Engines

HEAT TO ELECTRICITY GENERATIONCoolingAirconditionerElectricityCombustionFuelEmissionsCostFuelCostHeatPureCycle®PowerSystemElectricity

THE PURECYCLE ® POWER SYSTEM91ºC –149ºC*4ºC – 30ºC*** 195ºF – 300ºFHeat In – Power Out** 40ºF – 80ºF

PURECYCLE ® POWER SYSTEM• 272 kW gross baseload power• Zero fuel input costs – hot fluid• Low temp resource (91º C - 149º C)*• Modular and scalable for larger plants• Based on high volume manufacturedparts• Short lead time; rapid site deployment• 24/7/365 remote monitoring• High power plant availability* 195º F to 300º F

INSTALLATIONS – PURECYCLE® UNITSChena Hot Springs in AlaskaGeothermalGreen Houses in New MexicoGeothermalRaser Technologies UtahGeothermalTextile mill in GuatemalaWaste HeatOregon Institute TechnologyGeothermalDOE DemonstrationOil & Gas180,000 hours accumulated run time……98% availability

TURBODEN PRODUCT LINE~ 500 kW• High cycle efficiency (up to 24%)• Size flexibility: 400 kW to 12 MW• High field availability (> 98%)• Partial load operation (down to 10%)• Low Operation & Maintenancerequirements (~ 150-250 hrs/yr)1 to ~ 5 MW• Long life > 20 years• Simple, unmanned operation• Direct drive generator12 MWmodule• Remote monitoring and control

TD UNITS – MAIN COMPONENTSCondenser-RecuperatorElectricgeneratorElectriccubiclesORC turbinePreheaterEvaporatorFeed Pump1 MWe modular ORC unitORC heat input (thermal oil)ORC heat output (hot water)11

HR UNITS – STANDARD SIZES12

IC ENGINES: UP TO 10 % ADD’L POWERELECTRICPOWERORCTURBODENCoolingwatercircuitHeat dissipationsystem(dry or wet)Thermaloil circuitExhaustHeat recoveryexchangergas/thermaloilgasFilters /ChimneyELECTRICPOWERJacket WaterCoolingPURE CYCLECoolingwatercircuitHeat dissipationsystem(dry or wet)5

IC ENGINES: TD REFERENCE PLANTSProject ORC Module Site EnginesPisticci I TURBODEN 18 HR SPLIT (1,8 MWe) Pisticci 3 x 8 MWe Wartsila Diesel enginesOxon TURBODEN 6 HR SPLIT (0,6 MWe) Pavia 1 x 8 MWe MAN Diesel engineFinPower TURBODEN 6 HR DIR. EXCH. (0,6 MWe) Visano 1 x 7 MWe Wartsila Diesel enginePisticci II TURBODEN 40HR SPLIT (4,5 MWe) Pisticci 3 x 17 MWe Wartsila Diesel enginesCereal Docks TURBODEN 6 HR DIR. EXCH. (0,6 MWe) Portogruaro 1 x 7 MWe Wartsila Diesel engineEukrasia TURBODEN 6 HR SPLIT (0,6 MWe) CataniaBlue TowerTURBODEN 6 HR (0,6 MWe)Under constructionHerten (D)2 x 1 MWe JGS/GE gas engine +3 x 0,8 MWe JGS/GE gas engine +1 x 0,6 MWe JGS/GE gas engine2 x 2,1 MWe MWM gas engine(+ additional heat from process)UlmTURBODEN 10 HR cogenerative (0,8 MWe)Under constructionSenden (D)2 x 2 MWe JGS/GE gas engine(+ additional heat from process)Land & MarineBlue NG2 x TURBODEN 10 HR (0,8 MWe)Under constructionSouthall (UK)Beckton (UK)1 x 14 MWe MAN Diesel engine14

GAS TURBINES: UP TO 30% ADD’L POWERCoolingcircuitELECTRICPOWERHeat dissipation system(dry or wet)Thermal oil / Steam / Pressurised watercircuitsHeatrecoveryexchangerFilters /ChimneyGas Turbine15

GAS TURBINES: UP TO 30 % ADD’L POWERSGT-700 SiemensSGT-400SGT-500 SiemensORC suitable for heat recovery in:• Remote/unmanned locations with variable operating loads (e.g. gas compressor stations)• “Peak load” power stations (easy and fast start-up procedures)• Heavy duty / continuous applicationsNOTE: Indicative values assuming ambientair temperature of 15°C, Gas Turbinesoperating at nominal load;calculations based on Gas Turbine exhaustgas properties as reported in specificsuppliers web sites.16

HEAT RECOVERY APPLICATIONSTypical limitsGAS>480°F (250°C)LIQUID>195°F (90°C)STEAM / VAPORCement Glass Oil & Gas Chemicals Steel / NonFerrous Pulp & Paper Food Waste treatment Thermal Oxidizers Power generation 17

CEMENT PRODUCTION REFERENCEReference Case study: PRS gas waste heat recovery• Clinker production capacity: ≈ 5.000 ton/day• Heat source: exhaust gas @ 330°C• Gas cooled down to 220°C (extra heat used for rawmaterial pre heating)ORC electric power: About 2 MWeClient: CIMAR – ITALCEMENTI GROUP (Morocco)Under construction, start up Q2 20103 / 518

ELECTRIC ARC FURNACE EXAMPLE 1Reference Case Study: Billet re-heating furnace Production capacity: ~ 100 MT/h Heat source: exhaust gas @ 500°C (930°F) Gas cooled down to 150°C (355°F) No heat carrier: direct heat exchangeMain Exhaust Gas Characteristics: Absence of dust (natural gas firing) Variable conditions depending on mill operation, etc.ORC electric power: ~ 1 MWArchive pictureStudy for merchant and re-bar minimill – ItalySponsored by EU Life+ program3 / 519

GLASS INDUSTRYHeat source main properties:• High exhaust gas temperature• Constant operating conditions• Exhaust gas with moderate dust content• Exhaust gas must be cooled not below 200°CHigh temperature ORC cycle employed:ORC electrical efficiency up to 25 %3 / 520

SOLAR ORC APPLICATION21

ADVANTAGES – PWPS + TURBODEN• Products• Size flexibilityEPC/Turnkey or Equipment Only280 kW - 10 MW Building Blocks• Wide temperature range 90°C to - > 500°C• Deep ORC Experience• Proven reliability• Modularity• Aftermarket capability• Financial strength• Lead time30 yearsStandard designs/P&W Quality StandardsFactory assembled systemsGlobal Service Infrastructure / Available partsGuaranteed by Pratt & WhitneyTurboden - 10 mths, PC - 3 to 8 mths22

THANK YOU !www.turboden.comwww.pw.utc.comDavid Paul (david.paul@pw.utc.com)23