Stationary/Transportation Heat-to-Power Applications with CN300 ORC Technololgy

© 2014 Concepts ETI, Inc. All rights reserved.
STATIONARY/TRANSPORTATION
HEAT-TO-POWER APPLICATIONS
WITH CN300 ORC TECHNOLOGY
ASME Turbo Expo 2014
Exhibitor Presentation Stage
CCD Congress Center | Düsseldorf, Germany
Keith D. Patch
ORC Product Manager
Concepts NREC (CN )
+1 (781) 937- 4616
kpatch@conceptsnrec.com
Tuesday, June 17, 2014, 3:15 PM CET

2© 2014 Concepts ETI, Inc. All rights reserved.
Copyright Statement
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 Introduce presenter and company
 Organic Rankine Cycle (ORC) background
and history
 Heat-to-power applications
 Stationary applications
 Transportation applications
CN300 ORC turbogenerator product/benefits
 Initial 300 kWe product from Concepts NREC (CN)
 Low capital cost; minimizes O&M costs
 Customized aero design to match site requirements
 Custom designs ensure maximum system efficiency
Presentation Overview

 CN is a ≈50 year-old company,
with ≈100 employees
 72 patents granted, 19 patents pending
 39 employees have advanced college
degrees
 ORC engineering experience: from the
early 1970s to the present time
 Keith D. Patch is a 25+ year veteran
of the energy field
 Waste heat recovery, fossil fuels,
biomass, fuel cells, lithium-ion
batteries, and nuclear instrumentation
 Residential-, commercial-, industrial-,
and utility-scale
Introduction
Typical CFD Turbine Analysis Results

Market Opportunity of the
Waste Heat Problem
28% of the World’s Total
Energy Use Is Wasted but Is
Potentially Recoverable
Productive Utility/
Industrial Energy Use
Can recover 144 GWe of power: US$359B (at US$2,500/kWe)

World geothermal potential is 148 GWe
World biomass potential is 25 GWe
World solar thermal potential is 25 GWe
Natural energy + waste heat markets: 342 GWe or $854B
The World’s Natural Energy Market

 Thomas Howard, alcohol/ether engine, 1826
 Du Tremblay engine, France, 1850–56
 Ether ORC for marine steam engine
 Frank W. Ofeldt, U.S. Patent 279,270, 1883
 Naphtha ORC engine for marine power
 NREC founded, 1956; Concepts ETI, Inc.
founded, 1980
 1st modern ORC prototype, Harry Zvi Tabor
and Lucien Bronicki, 1961
 1st commercial ORC sale, Ormat, 1972
 CN staff active in ORC development, 1970s–1980s
 CN CN300 ORC development, began in 2011
ORC Development Timeline

Simple ORC System
Evaporator
Heat
Turbine/Generator
Electricity
Pump
Condenser
Rejected Heat
 An ORC is best suited for making electricity from low-
grade heat sources, using an organic fluid to match the
fluid’s properties with the temperature of the heat source

Above 50 MWe: steam Rankine cycle is the clear choice
 For primary power generation
 For high-temperature waste heat
 Although a 95 MWe geothermal ORC plant (2013) exists
Below 5 MWe: ORC is the clear choice
 For primary power generation
 For low-, medium-, or high-temperature waste heat
 Eliminate cost of steam boiler plant operators
 Eliminate cost of water, water treatment system, chemicals,
deaerator, etc.
Why Use the ORC Instead
of the Steam Rankine Cycle?

 28% of the world’s total energy use is wasted but is
potentially recoverable
 ORC natural energy market + waste heat equipment
market is 342 GWe or $854B
 ORC system efficiencies are 10–25%
 ORC systems are preferred over steam Rankine
cycle systems for most sub-5,000 kWe heat-to-
power applications
 ORC systems are the only heat-to-power solution
for low-temperature applications
Summary of ORC
Background and History

Stationary applications
 Large worldwide installed base
 Often sized over 100 kWe
• World’s largest ORC = 95 MWe unit
 Typical uses include:
• Geothermal power
• Reciprocating engine bottoming cycle
Transportation applications
 Representative ORC demonstration units
• Earliest demo: U.S. DOE-funded 36 BHP
demo in the 1970s–1980s (photo at right)
• Current DOE SuperTruck program
 Commercial products not yet available
Heat-to-Power Applications
Patent
Pending

 Natural sources
 Geothermal
 Biomass
 Solar thermal
 Waste heat recovery
 Waste treatment plants/
incinerators
 Power generation exhaust
 Glass and cement industry
 Oil and gas industry
 Chemical industry
 Steel industry
 Pulp and paper industry
Typical Stationary ORC Applications
Cumulative Worldwide
ORC Installations

 Truck OEMs must
meet stringent fuel
economy standards
 ORC fuel economy
improvement goal of ~6%
 Two-stage ORC turbine
has better performance,
but is too complicated
 Down-selected to a
single-stage axial turbine
 Turbine designed/built/
validated in on-road testing
ORC Design for Heavy Truck Engine –
CN/Cummins/U.S. DOE (SuperTruck)
Photo by Sarah Gerrity, Energy Department

CN Has the Solution to
Expand the Clean Energy Market
Market SolutionProblem
60% of the world’s
primary energy is
lost as waste heat
CN300–CN5000:
reliable, low-
total-cost devices
High capital expense
and high maintenance
cost of existing waste
heat-to-power systems

Commercial Product – CN300
Flow
Out
Flow
In
 Features
 Hermetically-sealed design
 Modular turbine cartridge
 Magnetic bearings (oil-free)
 Advantages
 Simplicity – eliminates all
seals, gears, couplings,
lube oil system, and oil
contamination
 Reduced capital and
O&M costs
 Reduced footprint
 Increased reliability
 Optimized performance
 Wide working fluid flexibilityOutput from 150 to 330 kWe

Competitive Advantages of the CN300

CN300 Specifications
Initial member of CN’s ORC Turbine Generator Unit (TGU) product line
Designed using CN’s Agile Engineering Design System®
 Gross power range
 150–330 kWe
 TGU speed
 20,000 rpm
 Turbine inlet temperature range
 180–425°F (80–220°C)
 Turbine casing inlet pressure rating
 700 psig [49 Bar (Absolute)]
 Turbine casing outlet pressure rating
 200 psig [14 Bar (Absolute)]
Turbine pressure ratio range
 2:1–25:1
 Working fluid compatibility
 R112, R113, R114, R134a, R236fa, R245fa
 TGU size
 42 in. x 24 in. x 34 in. (1.07 m x 0.62 m x 0.87 m)
 1200 pounds (544 kg)
 Electrical details
 400–480 VAC, 3-phase, 50–60 Hz
Agile Engineering Design System is a registered trademark of Concepts ETI, Inc.
Mach Number Contours
Through Flow Path
Flow Path

ORC heat-to-power systems are an established clean
energy technology
ORC heat-to-power systems can efficiently convert
renewable thermal energy and waste heat to
electricity
Widespread stationary and transportation ORC
applications exist
Recent advancements have improved ORC reliability
and virtually eliminated maintenance
The CN300 provides best-in-class first cost, operating
and maintenance costs, efficiency, and flexibility for
converting heat to ≈300 kWe of electrical power
Summary

Stationary/Transportation Heat-to-Power Applications with CN300 ORC Technololgy

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