ahmet durmaz waste heat recovery power generator
TRANSCRIPT
TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION< Confidential to TMEIC Corporation>
Ahmet DurmazTMEIC Corporation
Houston, Texas, USA
Waste Heat Recovery Power Generator
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• Increasing energy prices and CO2 emission controls
• 20-50% of industrial energy consumption released as waste heat
• Proven technology
Introduction – Why recover waste heat?
Current Situation• Mandate for “Green facility &
footprint”
• Convert waste heat into monetary value in the form of electricity
• Can be applied to several industrial applications
Industry changes
Huge potential in waste heat recovery although not knownAs other alternative energy types like solar, wind, biomass
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DIESEL ENGINES:
• Typical Diesel Engine Shaft Power Efficiency : ~ 40-45% • Exhaust Temperature: 850 – 950 °F• Exhaust Gas Thermal Loss: ~ 30-35%• Jacket Cooling Thermal Loss: ~ 15-20%
GAS TURBINES:
• Typical Gas Turbine Shaft Power Efficiency : ~ 40-45% • Exhaust Temperature: 800 -900 °F• Exhaust Gas Thermal Loss: ~ 50-55%
Waste heat sources in an Oil & Gas complex
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High Pressure Organic Working Fluid Vapor
BASIC COMPONENTS OF ORC UNIT
Organic Rankine Cycle (ORC) Generator
Heat SourceThermal oil or
high pressure hot water
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Units are available from 250 kW up to 10 MW
ORC Power Generator Unit
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• Working fluid R245fa or Silicon based depending on the resource temperature
• Heat source: Hot water or Thermal Oil 195–580F (91°-305°C)
• Cooling requirement: Water 39F–109F (4° - 43°C)
• Controls: PLC with Remote monitoring Web-based gateway Operation
• Designed for unattended operation
• Enclosure Not required
ORC System Properties
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ELECTRICITY
EXHAUST
Waste Heat Recovery & Power Generator
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Waste heat recovery diagram for Gas turbines & Diesel Engines
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• Turbine Shaft Power: 10,000 HP ( 7457 kW)
• Exhaust Waste Heat Recovery : 9,750kW
• Net ORC power : ~ 2243 kW (at 23% efficiency)
• Thermal Oil: ORC inlet 570F / ORC outlet 410F (300C / 210C)
• Thermal Oil Flow: ~ 102 lbs/sec ( 46 kg/sec)
• Cooling Water : inlet 81F / Outlet 108F or ( 27 C / 42C)
• Cooling Water Flow: ~ 1900 GPM ( 430 m3/h)
• Heat Exchanger Size : 33.2 MMBTU
~30% of Turbine Shaft Power
Sample data for Gas Turbines
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0.00
2.00
4.00
6.00
8.00
10.00
12.00
0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12 0.13 0.14 0.15 0.16
Pay
off Y
ears
Price of Electricity ($/kW)
Return On Investment (without incentives and not considering future escalation of electricity prices)
$2000/kW
$2500/kW
$3000/kW
$3500/kW
ORC Payback calculations
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• Auto Start/Stop
• Ability to work with low temperature heat source
• Partial load capability down to 10% power with high efficiency
• Low maintenance, no operator required for operation
• Design life ~ 20 years
• Quiet Operation
• High availability > 98%
ORC Advantages
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Application Examples
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Patent Pending Configuration
Other ORC applications
Steel Mills
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ORC generator slab furnace evaporative cooling application
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Recovery from slab furnace evaporative cooling system:
- Installed power capacity 1 MW- Resource Temperature : 140C- In operation since September 2011- Typical waste steam was about 16 tons/hour
Recent Heat Recovery Project in Turkey
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Recent Heat Recovery Project in Turkey
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NO MORE WASTE OF STEAM
BEFORE AFTER
Recent Heat Recovery Project in Turkey
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Recent Heat Recovery Project Pictures
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Recent Heat Recovery Project Pictures
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Recent Heat Recovery Project Pictures