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ORC heat recovery systems use various hydro-chloro-fluoro-carbon (HCFC) refrigerants such as R245fa (1,1,1,3,3-pentafluoropropane) and hydro-fluoro-carbons (HFCs), or light hydrocarbons such as n-pentane and isobutene, or toluene. The HCFC and HFC fluids have limited temperature capability due to their thermal decomposition to highly reactive hydrochlorides and hydrofluorides. The high global warming potential of these fluids has led to regulatory pressure to phase these fluids out of production and use. Hydrocarbon working fluids present significant flammability hazards. For both classes of fluids, direct heat exchange from a high temperature source is generally avoided by use of an intermediate heat transfer fluid loop, which adds significant installation cost to ORC systems. The heat transfer fluids also have upper temperature limits in the 572 to 662 F (300 to 350 C) range, which limits the maximum working fluid temperature to lower operating temperatures. For higher temperature applications, the temperature limit of the heat transfer fluid then requires use of a diverter and bypass stack to accommodate continued operation of the main process when the heat recovery system is not operating. Due to the superior thermal stability and non-flammability of CO2, direct heat exchange from high temperature sources is possible, permitting higher working fluid temperature (and thus higher cycle efficiency). With proper material selection and heat exchanger design, the ScCO2 system is also capable of “dry-running,” where the main process can operate uninterrupted when the heat recovery system is not operating, thus eliminating the diverter and bypass stack. Figure 4 compares the power output for a standalone LM2500 power generation turbine compared to the power output of the LM2500 integrated with various heat recovery technologies. The analysis was conducted using published performance data for the gas turbine, the competing waste heat recovery technologies, and an Echogen utility-scale system currently under development. Modeling results show that compared to steam-based and Organic Rankine Cycle systems, the Echogen Cycle delivers higher performance, exceeding the output of single-pressure Heat Recovery Steam Generators by a factor of 1.13 and comparable ORC systems by a factor of 1.48. The Echogen heat engine technology is a smaller and lower cost waste heat recovery solution compared to traditional power generation technologies such as steam turbines, heat recovery steam generators and ORC systems. As a platform technology, it is easily scalable from 250 kW to greater than 50 MW to support the widest possible variety of industrial and utility applications. Echogen heat engines are thermal source agnostic, meaning a wide range of heat sources are suitable for energy conversion to electricity. The thermal engines work at operating temperatures from 400 F to greater than 1,200 F (204 C to greater than 650 C) and conditions where other devices cannot operate, enabling a greater amount of waste energy to be recovered and transformed to electricity or process heat. Field Testing at American Electric Power As shown in Figure 5, Echogen completed the design and fabrication of a 250 kW system in late 2009, and the system was installed during 2010 at the American Electric Power (AEP) Walnut Test Facility located in Groveport, OH for beta testing. The 250 kW system skid measures only 10 x 12 x 20 ft (width x height x length) and weighs less than 49,000 lbs which allows for highway and truck transport without special Department of Transportation (DOT) permits. Located within the skid are all of the components previously described in Figure 1 including the main system pump, recuperator, condenser, system 5PDF Image | Transforming Waste Heat to Power through Development of a CO2
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