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Powerhouse Waste Heat to Energy Project Final Report 480V loads in the steel and concrete power plant buildings as well as export any surplus to the 4160V new plant generation bus for delivery to the distribution system. The maximum allowable power that can be exported to the steel building is 332 kW via the available 400A 3 phase 480V plant-to-plant station service feeder between each MDP. Refer to electrical one-line in Appendix A. Should the need arise for more than this amount then the existing 4160V concrete plant system would need to be upgraded or Units 8 or 9 be removed to accommodate. Calculations show that when all units sustain 75% loading (utilizing exhaust gas and jacket water less building heat) approximately 600 to 650 kW of ORC power could become available. This level of loading would require sustained electrical town loads of 11 MW which is over 100% of current day town loading. 3. ORCEvaluation Given the many technical design constraints EPSI has determined that both waste heat systems (engine jacket and exhaust gas) are ideally suited (both electrically and physically) for ORC units in the 40 kW to 80 kW range and would be capable of operating around 190F to 300F continuously. This restricts the selection process to only a very few ORC manufacturers today which include Ener-G-Rotors, Electratherm, Turbo Thermal LLC, and GE. Many other manufacturers were considered but were eliminated from the “potential candidates” list for this project because of lack of interest, operating temperature problems, or unit size scaling issues. Ener-G-Rotors is still currently in beta testing mode and does not expect to produce a commercially available 35 kW to 50 kW unit until December 2013. Electratherm produces the commercially available Green Machine Series 4000 unit that is a 50 kW unit which is ideally suited for use on the jacket water system and/or exhaust gas heat system. Turbo Thermal LLC produces a 240 kW or 320 kW ORC unit that can be broken down into three or four 80 kW units which appear to be more ideally suited for the exhaust gas system. GE Clean Cycle units are 125 kW units that may also work in leau of the Turbo Thermal units on the exhaust gas system. The engine jacket water waste heat to energy project was evaluated in the EPSI 2008 report. During the 2011 Request for Qualifications process only Pratt/Whitney UTC responded. Unfortunately, Pratt/Whitney UTC will now only sell a minimum lot of ten units per order which eliminates them from the “potential candidates” list for this project. Below is a brief description of the Electratherm and Turbo Thermal ORC units and the rationale for their further consideration. The summary of this report lists each of the other manufacturers not mentioned within this section. The reasons for their elimination from the “potential candidates” list are briefly outlined in the summary of this report. (OHFWUDWKHUP*UHHQ0DFKLQH The Electratherm (ET) units are more customizable than any other ORC vendor information to date. ET, through their website and communication with the ET representative, has two standard models which fit a variety of applications and unit (heat source) sizes. The electrical output range is also ideally suited to run two 50 kW units for each engine jacket. The ET Green Machine 4000 is a 50 kW unit that consists of a 480V 3 phase 100 HP screw compressor operating in reverse process. The generator consists of a Marathon 50 kW 10/22/2012 P a g e | 3-10PDF Image | Powerhouse Exhaust Gas Waste Heat to Energy Project
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