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1. Summary Powerhouse Waste Heat to Energy Project Final Report The City of Unalaska has requested that Electric Power Systems, Inc. (EPSI) provide feasibility design services for the installation of an exhaust gas waste heat to electric energy reclamation project. This report explores the feasibility for the various economic and technical solutions available for implementation. Upon investigation, EPSI found that the exhaust gas waste heat reclamation system will require an additional waste heat line between the old and new power plants, three exhaust stack boiler units (one on each exhaust stack), necessary higher temperature ORC units, associated seawater cooling and heat exchanging system, supplemental radiator system, associated valving and instrumentation package, one 480V 3 phase feeder stepped up to 4160V and connect into existing Unit 8 and 9 (after Unit 8/9 removal) power lines, and a remote monitoring SCADA interface. The exhaust gas waste heat project is economically feasible once Unalaska town loads reach minimum continuous year round base loads of 7.5 to 8 MW. Economic feasibility may also become a reality if fuel prices sustain an average price of over $4/gallon. As any one of these factors increase over time the economic feasibility will become more compelling. This conclusion is based on the current available boiler and ORC manufacture data being accurate, conformance to all current and future environmental constraints, and all technical/design issues being appropriately addressed. The environmental constraints that this report’s conclusions are bounded by concern both air and seawater. It is understood that the current ADEC air permit temperature constraints have been relaxed to allow for the use of exhaust gas stack boiler units such that final stack outlet temperatures to atmosphere do not drop below 350F. However, it should be noted that current ADEC/EPA permitting increases to seawater outlet temperatures have not been permitted to be raised to adequate levels. To support the needs of an exhaust gas waste heat project the ADEC/EPA would need to review and permit elevated seawater outlet temperatures before the project could be considered viable. If such permitting cannot be achieved then a costly supplemental radiator system will need to be implemented. For the purposes of this report the cost of supplemental radiators was included. Performance data, prices, drawings, parts, service, warranty, and lead time information was collected from ORC and exhaust gas boiler unit manufacturers. Below are the manufacturers that have been contacted, equipment reviewed, and evaluated for this report. Below each manufacturer listed is a brief synopsis of their equipment. A more detailed discussion follows further within this report. This report does not focus on ranking and comparing various ORC manufacturers for selection purposes but only gives a cursory review of likely vs unlikely candidates for further investigation. This report will tend to focus on the exhaust gas boiler manufacturer’s pros/cons of each and base pricing upon a select manufacturer solely for the purpose of cost to benefit evaluation. o Electratherm (ET) Green Machine This ORC manufacturer produces 50 to 65 kW units. These units were tested at the University of Alaska Fairbanks Mechanical Engineering 10/22/2012 P a g e | 1-4PDF Image | Powerhouse Exhaust Gas Waste Heat to Energy Project
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