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Powerhouse Waste Heat to Energy Project Final Report Department and yielded 5.5%, 7%, and 7.5% total net efficiencies at operating temperatures of 155F, 195F, and 215F, at various flow rates, respectively. Given the flows, temperature differentials, and total available BTUs for the jacket water system at Unalaska it is expected that each Wartsila or Cat will operate two 50 kW machines (plumbed in parallel) at a net output of 39 kW each. This expected net output has been confirmed both by UAF testing and Electratherm trials and calculations. Temperature differentials are not sufficiently high enough to justify the installation of the more expensive 65 kW machines. o United Technologies Corp (Carrier) (UTC/Pratt Whitney) This ORC manufacturer primarily focuses on 1 MW unit sizes and larger. However, they do make a 250 kW unit that has only become readily available in the last 5 years. Its optimal operating temperatures are also found to be higher than the 195F that Unalaska can deliver. However, the unit can operate to a limited degree at these lower temperatures. Furthermore, Pratt/Whitney is only willing to sell the 250 kW unit size in lots of ten which is well outside of the scope and budget of this project. o Infinity Turbine LLC This ORC manufacturer offers promise in the 200 to 300 kW unit sizes but also has difficulty working with the temperatures. Additionally, they require a money down payment before they will divulge any necessary design information to determine feasibility. AEA grant funding restrictions generally do not allow such payments without proper feasibility reviews. o Ormat o Ener-G-Rotors o GE This ORC manufacturer is currently beta testing their 35 to 60 kW units that use a special ORC refrigerant that produces highest efficiencies at lower temperatures around 185F. They do not expect a fully functional unit for sale until the end of 2013. GE currently makes a higher temperature ORC unit that grosses 125 kW output. The technology utilizes a hermetically sealed 125 kW high-speed generator and turbine in a single package. It has no external rotating seals and no gearbox. It also uses magnetic bearing technology that creates nearly zero friction losses and minimizes maintenance. It utilizes power electronics to convert high frequency to DC power which is then reconditioned to 60 Hz usable power output. This unit may have application for the exhaust gas waste heat reclamation project. The minimum operating evaporator temperatures require 300+F which can be achieved from the exhaust gas boilers reviewed in this report. This exhaust gas and ORC manufacturer produces units that operate at 1000F+ temperatures and utilizes unit sizes much larger in scale than Unalaska would necessitate. 10/22/2012 P a g e | 1-5PDF Image | Powerhouse Exhaust Gas Waste Heat to Energy Project
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