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Powerhouse Waste Heat to Energy Project Final Report induction motor run in reverse operation. The induction motor makes for an inherently safe concept such that no export of power is possible should there be loss of AC power on the prime power source side. Additionally, this eliminates the need of synchronization equipment. The entire assembly (including control panel) sits on one skid and has a physical footprint size of approximately 6’ x 8’ x 8’. The first floor space, where recently retired units 1 through 6 resided, is physically restricted to only accommodate units of this size or smaller. Up to three separate units can fit within this existing space. Room for a fourth unit may be provided if the old operator’s office becomes available for renovation to accommodate. Electratherm is willing to customize any of its units to meet the needs of the facility. For this reason information concerning the “base” units has been provided. Customization of the units to optimize the recovery would cause the price to adjust accordingly. Titanium or cupro-nickle in shell and tube configuration heat exchangers are options for use with the sea water cooling system at additional cost. 0DLQWHQDQFH 2SHUDWLRQ ± The ET ORC has three moving parts which require maintenance. In general, ET recommends that the turbine drive belt, should be changed annually even though it is rated for over 20,000 hours of operation. The cost of the drive belt is $300. ET has determined that each unit would require 1.5 cents per kW-hr for maintenance over a one year period. This cost would include periodic inspection of the unit (lubrication, seals, performance) and cleaning of the units’ sea water heat exchanger and replacement of the drive belt. ET is a new company/manufacturer and unfortunately does not have years of previous ORC experience to be able to adequately predict the longevity of their units. But, from a design perspective, their unit has 3 moving parts. Based on this fact alone, we would anticipate that the unit should have well over a 20 year life expectancy. 7XUER7KHUPDO//& This ORC manufacturer makes two different sizes of units that could work well for this project. The first size is a 240 kW unit which consists of 3 (three) 480V 3 phase 80 kW rated expander/generators working in unison. The second size is a 320 kW unit which consists of 4 (four) 480V 3 phase 80 kW rate expander/generators working in unison. The optimal operating temperatures are at 300F but can also run at the expected 230F temperatures at the expense of efficiency as mentioned below. Both units (240 kW and 320 kW) each fit within a 20 foot shipping container and can be broken down and refitted to most any space. The largest pieces of gear consist of three major components: 1) Three or Four expander/Generator skids each @ 30”W x 30”H x 72”L; 2) One common surge tank @ 72”H x 48” diameter; 3) One common control panel @ 72”H x 48”W x 30”D (double door). Approximately every 25F above 230F up to 300F an extra percentage point of efficiency is achieved. For example, at 225F output to the Turbo Thermal ORCs one can expect 8% efficiency. At 250F one can expect 9% efficiency, 10% efficient @ 275F, and 11% efficient @ 300F. For this analysis it is assumed that the exhaust gas boilers can be turned up to 300F output to the ORC units to achieve 11% efficiency from the Turbo Thermal ORC units. 10/22/2012 P a g e | 3-11PDF Image | Powerhouse Exhaust Gas Waste Heat to Energy Project
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