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Waste Heat Recovery Power Generator

Ahmet Durmaz
TMEIC Corporation
Houston, Texas, USA

TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION


< Confidential to TMEIC Corporation>
Introduction Why recover waste heat?

Current Situation Industry changes


Increasing energy prices and Mandate for Green facility &
CO2 emission controls footprint

20-50% of industrial energy Convert waste heat into


consumption released as waste monetary value in the form of
heat electricity

Proven technology Can be applied to several


industrial applications

Huge potential in waste heat recovery although not known


As other alternative energy types like solar, wind, biomass

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Waste heat sources in an Oil & Gas complex

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%

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Organic Rankine Cycle (ORC) Generator

BASIC COMPONENTS OF ORC UNIT

High Pressure Organic


Working Fluid Vapor

Heat Source
Thermal oil or
high pressure hot water

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ORC Power Generator Unit

Units are available from 250 kW up to 10 MW

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ORC System Properties

Working fluid R245fa or Silicon based depending on the


resource temperature

Heat source: Hot water or Thermal Oil 195580F (91-


305C)

Cooling requirement: Water 39F109F (4 - 43C)

Controls: PLC with Remote monitoring Web-based gateway


Operation

Designed for unattended operation

Enclosure Not required

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Waste Heat Recovery & Power Generator

EXHAUST

ELECTRICITY

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Waste heat recovery diagram for Gas turbines & Diesel
Engines

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Sample data for Gas Turbines

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


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ORC Payback calculations

Return On Investment
(without incentives and not considering future escalation of electricity prices)
12.00

10.00

8.00
Pay off Years

$2000/kW

6.00 $2500/kW

$3000/kW

$3500/kW
4.00

2.00

0.00
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

Price of Electricity ($/kW)

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ORC Advantages

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%

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Application Examples

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Other ORC applications

Steel Mills

Patent Pending
Configuration

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ORC generator slab furnace evaporative cooling application

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Recent Heat Recovery Project in Turkey

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

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Recent Heat Recovery Project in Turkey

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Recent Heat Recovery Project in Turkey

BEFORE AFTER

NO MORE WASTE OF STEAM

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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

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