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Economics Table 1 - Waste Heat to Power Cost Comparison Installed Costs, $/kW $2,000 - $4,000 WHP Generating Costs Cost Component Amortized Capital, $/kWh O&M Costs, $/kWh Total Power Cost, $/kWh $0.055 - $0.125 $0.005 - $0.020 $0.060 - $0.125 Source: ICF International estimates, 2012 The total cost to install WHP systems include the costs associated with the waste heat recovery equipment (boiler or evaporator), the power generation equipment (steam, ORC, or Kalina cycle), power conditioning and interconnection equipment. It would also include the soft costs associated with designing, permitting and constructing the system. The installed costs of Rankine cycle power systems (steam, ORC or Kalina) are fairly similar, differing more as a function of project size and the complexity of site integration than type of system. A first-cut estimate of the cost of producing power from WHP systems is presented in Table 1. Representative costs are shown that represent a range of project sizes (<400 kW to > 5 MW) and site complexity. Capital costs are amortized over a 10 year period based on a cost of capital of 15 percent14 and 7,500 annual operating hours. Operation and maintenance (O&M) cost estimates can vary widely. Rankine cycle power systems themselves have relatively low maintenance costs. However, maintenance requirements of the heat recovery boilers and balance of plant must also be included and these can vary by technology and by site conditions. As an example, steam systems may require on-site boiler operators while ORCs can often run unattended. O&M costs of $0.005 - $0.020/kWh were used for this comparison to reflect the wide range of maintenance requirements that might be experienced. There are no fuel costs for true waste heat to power projects (i.e., no supplemental fuel use). Current Market Status Current market penetration of WHP projects in the United States is limited compared to other types of CHP. There are currently 34 WHP projects in place totaling 557 MW of power generation capacity in the United States, as shown in Table 2. Most of the existing industrial WHP systems use a heat recovery boiler, steam turbine, and generator, which are limited to waste streams with relatively high temperatures (> 500 oF). Other options are entering the market that can be used at lower temperatures and smaller sizes, including ORCs, ammonia-water systems (e.g., Kalina cycles), and thermo-electric generators (still in development) that use solid state systems that require no moving parts and sit directly in the waste stream. Utilizing liquid streams below 200 oF and gas streams below 500 oF typically remains economically impractical with today’s technologies, however. Conversion to electricity is less efficient with all these technologies compared to traditional electric generators, and project costs currently run high for a variety of reasons, including the cost of the equipment and the cost of integrating the waste heat recovery system with the waste heat source. WHP is generally considered only when the waste heat cannot be used directly within the process, or other recovery methods are not practical within the facility. While the costs of these systems currently remain high, and commercial demonstration is limited, the technologies continue to evolve rapidly. 14 The relatively high cost of capital of 15 percent reflects current perceptions of technology and market risks. 6 Table 2: Existing WHP Projects in the United States by Application Industries Sites Capacity MW Chemicals Petroleum Refining Non-metallic Mineral Industries Primary Metals Landfill Gas Power Natural Gas Compressor Stations Total Source: CHP Installation Database, DOE/ORNL, 2012 12 224 5 131 2 10 2 127 1 <1 12 65 34 557PDF Image | WASTE HEAT TO POWER SYSTEMS
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