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Optimizing Heat Recovery Systems for Power Generation in Rural AK

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Optimizing Heat Recovery Systems for Power Generation in Rural AK ( optimizing-heat-recovery-systems-power-generation-rural-ak )

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achievable through the use of an organic Rankine cycle (ORC) system, which uses waste heat contained in diesel engine jacket water and exhaust. The second is to evaluate feasibility, operation and maintenance requirements, and payback time of applying a selected ORC system. The third is to develop guidelines for ORC system selection, operation, and maintenance; and to evaluate the potential impact of applying waste heat ORC systems on rural Alaska economy, fuel consumption, and emissions and greenhouse gas reductions. The fourth is the performance and economic comparison of two ORC systems. One ORC system is a 50kW system, which uses screw expander, comes under emerging technology. The second ORC system is a Pratt & Whitney (P&W) 250 kW unit which uses radial turbine belongs to the category of well-developed technology. Due to an unexpected turbo charger break down of the Cordova diesel generator set, to which the 250kW ORC system will be installed, performance information of the 250kW ORC becomes unavailable at this moment. Therefore, the result of the fourth task, comparison in performance of the two ORC systems, is not included in this report and will be provided in a make-up report in the future. This report presents details of each step performed along the process leading to the completion of this project. The rest of the report begins with a description of the project preparation (Chapter 2), which includes a survey of waste heat recovery technologies for power generation capacities lower than 100kW, the final selected technology for testing, and the layout of required elements for test plan and test site. Chapter 3 discusses ORC principles, modeling and simulation, and how the simulation results can be used for preliminary designs and selections of components and prediction of system performance under different waste heat and cooling conditions. Chapter 4 describes the layout of the final design for the ORC testing, details of the testing system and its components, and procurement. The final design layout has been obtained through a few design iterations and the design was based on the availability of the test space, estimated project cost, resources availability, codes and standards, and timing. The final selected testing location has both heating (steam) and cooling (water) sources available for the ORC system. The final testing system includes a closed steam loop coupled with a closed hot water loop for heating, an open cooling water loop for cooling, an electrical circuit for power up-loading and consumption control, instrument and signal process circuits for data acquisition/performance monitoring and control, and a dedicate internet line for remote monitoring and controls. Detailed designs of the testing system were completed through the cooperation between the engineers of ACEP, facility services, and power plant and students and faculty members of the ME department on the UAF campus. Associated management personnel have also contributed a lot on schedule and resources controls. In addition, many of them are volunteers. The last section of this chapter is about procurement, in which components purchased and receiving schedules are mentioned and some of the difficulties encountered in procurement are also pointed out. Chapter 5 gives a description about installation and instrumentation. This includes installation methods applied to the thermal fluid system, data acquisition system for data collection and monitoring/system controls, calibrations of the measurement devices, etc. Chapter 6 briefly describes the commissioning process and related issues, such as, limitations and constraints of the ORC system, new findings, etc. during the commissioning. Chapter 7 describes equipment used and equipment arrangement for testing, scheduling, and cases included in performance testing. Chapter 8 presents details 7

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