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Powerhouse Waste Heat to Energy Project Final Report 5. As part of the detailed design for the ORC’s a revision to the facility sea water cooling permit may be required to allow for a more elevated discharge seawater temperature than originally permitted. Preliminary data from the ORC vendors indicates a sea water temperature increase of 20F. No sea water temperature restriction was provided to the ORC vendors. Something to consider is that as waste heat is converted to electricity the amount of waste heat/cooling water which requires cooling will be reduced. When the ORC’s are operating at their peak output, the sea water discharge temperature could decrease. If the sea water permit cannot be successfully modified then a supplemental radiator will be needed to remove excess heat prior to dumping remaining heat back into the seawater. 6. According to Wartsila 12V32 design information (from original 2005-2007 design effort) the units are designed to allow a total exhaust restriction of 12 inches of water column. It’s currently estimated that the total system back pressure with the exhaust gas boiler will be 11.35 inches of water column. This is a worst case operating point without detailed design. As such the gas boiler control package should include differential pressure monitoring and alarming. 7. One or two motor operated valves to control sea water flow to the heat exchangers and the bypass around the heat exchangers will be required. This is only a preliminary look at the system, during the detailed design; this strategy would have to be verified. 5. 8. The ORCs operate best at steady state conditions and are not suited for operation on a peak-shaving or back-up unit. This would best be provided by the Wärtsilä units as the base loaded machines. Currently, only one Wartsila or the other is used on a nearly 24/7/365 basis. Eventually, as the town loads increase the Cat C280 will be utilized in a similar fashion at which point another exhaust gas stack boiler could be implemented. 9. It’s suggested that a 50/50 Dowfrost HD/Water solution be used to transport the 300F exhaust gas boiler outlet temperatures expected. This will provide the optimal heat transfer, eliminate chemical breakdown, satisfy environmental requirements, and contain the needed corrosion inhibitors. Conclusion and Recommendations EPSI recommends that the engine jacket water waste heat project be fully constructed to completion so as to reap the most immediate and rewarding benefits possible. This should be accomplished through the installation of 4 (four) 50 kW Electratherm Green Machines installed on the lower floor of the concrete plant where units 1, 2, 3, 4, 5, and 6 used to reside. Since plant operating procedure is based on maintaining N-1 unit contingency (plant always allows for one of the largest units to be offline at all times) it is not necessary to evaluate for loading above N-1 plant capacity. As funds become available the project could be expanded to include the use of an exhaust gas waste heat system. EPSI recommends that this be accomplished via the use of two 240 kW Turbo Thermal LLC ORC units (or any equivalently sized units capable of effectively handling 230F to 300F heat transfer fluid) installed on the second floor of the concrete plant building after demolition of units 8 and 9 is accomplished. This will open up the needed floor space for any supplemental radiator system, 480:4160V step-up transformer and 4160V cabling needed while maximizing the use of the available exhaust gas waste heat available for electric conversion. EPSI recommends that one Cain Industries gas boiler unit be installed on each of the three steel plant exhaust stacks (Units 10, 11, and 13). Cain Industries boilers are chosen because 10/22/2012 P a g e | 5-13PDF Image | Powerhouse Exhaust Gas Waste Heat to Energy Project
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