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Powerhouse Waste Heat to Energy Project Final Report o TAS This ORC manufacturer produces their smallest units at 800 kW which is of a much higher scale and output than Dutch Harbor can support. o Turbo Thermal LLC This ORC manufacturer produces units in the 80 kW size and can bundle 3 or 4 units together in a modular package for a total maximum net output (after pump load is subtracted) of 225 to 300 kW. The R123 refrigerant they use in their units yield a theoretically calculated 7.6% and 11% efficiencies based on the total available jacket water heat and exhaust gas heat sources @ 195F and 300F, respectively. This ORC manufacturer appears to have the most comprehensive calculation foundation upon which their efficiency numbers are based. These efficiencies are also in agreement with Electratherm’s actual tested performance values. o Echogen This ORC manufacturer produces 200 to 300 kW units that operate in the 450F to 1000F operating temperatures. This will not work for this project as 300F temperatures are the maximum available temperatures that can be delivered at Dutch Harbor. o Calinetix This ORC manufacturer is no longer in business having been recently purchased by GE. Some of the Calinetix technology may have been adopted by GE. o Cain Industries, Inc. This exhaust gas boiler unit manufacturer produces a unit than can provide hot water temperatures in the 215F to 230F range where most ORC manufacturers prefer to operate. The Cain is least expensive and largest of the exhaust gas boiler units evaluated. It has several advantages that make it the most affordable of all units throughout its life. Cain provides a complete self-monitoring and self-cleaning low maintenance product that would suit the needs of the project. The controls package monitors in/out exhaust gas temperatures to avoid condensation of sulfuric acid. It also monitors exhaust gas back pressure (to avoid compromising engine efficiency) and provides regular self- cleaning cycles utilizing either steam or compressed air. Maintenance access points are readily available, includes integral exhaust bypass valve and valve controls, and there is good relatively local support of this product. Approximate material cost (not including installation labor) per boiler with all controls included is $235,000. o Maxim This exhaust gas boiler unit manufacturer produces a unit that can provide hot water temperatures in the 215F to 230F range where most ORC manufacturers prefer to operate. They do not offer the same built-in ready-to-go self-monitoring package that Cain does and would thus require additional cost to integrate a controls package to be comparable 10/22/2012 Page |1-6PDF Image | Powerhouse Exhaust Gas Waste Heat to Energy Project
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