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Powerhouse Waste Heat to Energy Project Final Report Actual current available heat only from Wartsila or Cat exhaust gas energy conversion at the gas boiler 5,775,000 or 5,789,000 BTU/hr, respectively (building heat to be supported on jacket water system). Exhaust gas boiler is conservatively estimated at 90% efficient. This means that 5,197,500 BTU/hr of waste heat energy can be expected to be delivered to the ORC units from each Wartsila and 5,210,100 BTU/hr from the Cat. Current energy production reports reveal that Unalaska is produces 15.5 to 16 kWh per gallon of fuel consumed. This report will use 16 kWh/gal for evaluation purposes. From correspondence with Electratherm and Turbo Thermal LLC technical representatives for Units 10, 11, and 13 it appears that at most the following waste heat energy could be reclaimed from each of the indicated units: Wartsila or Cat C280 jacket water only: Expected ORC output 78 kW after building heat is served (39 kW on each of two separate Green Machines) Wartsila or Cat C280 generator exhaust via exhaust stack boiler: 167 kW per unit (11% ORC efficiency and 90% boiler efficiency). Recommended plant operating Temperatures: Exhaust boiler supply temperature (hot): 300 degrees F Exhuast boiler return temperature (cold): 250 degrees F or as recommended by boiler manufacturer Waste heat System operating: To ORC: 300 degrees F Building Heat: 250 Degrees F Concrete powerhouse building structural Generator units 1 through 6 have been removed from the first floor back room of the old power plant building, leaving space for installation of the new ORC units on this concrete slab-on- grade floor, making structural analysis unnecessary. Additionally, construction on the first floor will be the least expensive as all hot water, cold water, and electrical connection points are located on the first floor. Preliminary evaluation has shown that the second floor can bear up to 100 lbs/sq. ft. Detailed structural design will be needed to determine and avoid compromising the rebar. The UTC 250 kW unit weights appear to fall below this weight restriction and can be therefore safely assumed that most any manufacturer of this size unit will also meet the weight restrictions. For the purposes of this report costs will be focused only on the first floor construction. Electrical Integration of either ORC Unit(s) The electrical modifications required for the installation of the ORC units are rather limited in scope as they do not require many modifications to the existing facilities. The ET Green Machine may be custom ordered to generate at various voltage ratings. The intent will be to order the ORC in the standard 480V 3-phase configuration and connect it to the existing 480V building service in the concrete power plant. This will allow the ORCs to serve all 10/22/2012 P a g e | 2-9PDF Image | Powerhouse Exhaust Gas Waste Heat to Energy Project
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