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Power Generation The DOD-funded ORC integration and replacement project that will deploy later this year is comprised of two 40 ft. (12 m) ISO shipping containers. Utilizing Waste Heat For Power Advanced engine cooling with economic payback; DOD project demonstrates up to 12% increase in fuel efficiency r/min, considerably less than turboex- panders, according to ElectraTherm. Unlike high-speed turboexpanders, screw expanders are robust units that tolerate “wet” dual-phase flow. “This allows a very robust and cost-effective design for the Green Machine that can tolerate perturba- tions in both temperature and flow with turn down ratios of 6:1 avail- able on demand,” said John Fox, CEO of ElectraTherm, Inc. “This is particularly advantageous in low tem- perature waste heat streams such as engine jacket water. Our Green Ma- chine design is simplified and elimi- nates lubrication reservoirs, oil cool- ers, pumps and land filters, creating a simple, robust and efficient system with fewer parasitic loads and main- tenance requirements.” The Green Machine acts as the en- gine’s radiator, so the engine-driven radiator fans can actually be discon- nected (or eliminated completely for a new installation), allowing more work to be performed by the engine to generate additional electricity. In effect, the engine’s waste heat be- comes a source of cost savings by dis- placing the radiator’s capital cost and parasitic load. Between the DOD project and the machines currently running in the field, ElectraTherm said it increases fuel efficiency up to 12%, depend- ing on engine size and configuration, and site conditions while featur- ing simple installation, mobility and low maintenance. There are multiple benefits to in- tegrating an ORC heat to power gen- erator with an engine gen-set: the additional electrical output from the conversion of the waste heat to elec- tricity with no additional fuel con- sumption or emissions, and the re- duction or elimination of the parasitic load from the engine cooling fans. In hot climates or seasonally high ambi- ent conditions, which often coincide with peak demand, the engine’s de- rate can be reduced due to the added cooling effect of the ORC, thereby increasing the power output of the engine. “The additional benefits from Continuous duty gen-sets provide base-load power generation in di- verse applications around the globe. However, high fuel costs and engine maintenance are pain points felt by operators. A low-maintenance path to significant fuel savings and lower emissions is what the U.S. Depart- ment of Defense (DOD) had in mind when they approached ElectraTherm to integrate the company’s Green Machine waste heat to power (WHP) generator with a 1.1 MW Cummins KTA-50 generator. ElectraTherm specializes in small- scale, distributed power generation from waste heat, utilizing Organic Rankine Cycle (ORC) and propri- etary technologies to generate power from low temperature heat ranging from 77o to 116°C. The company’s WHP technology converts various sources of heat into power, including internal combustion engines, small geothermal, biomass, concentrated solar and process heat. To date, ElectraTherm said it has deployed 42 units worldwide, with a cumulative 250 000 operating hours and over 97% availability. October 2014 Diesel & Gas Turbine Worldwide ElectraTherm’s primary market is waste heat from stationary internal combustion engines. Typical sites for these engines include prime power production in remote areas, island and developing nations, biogas gen- sets including landfill and waste water treatment plants, natural gas compression stations and renewable biofuels. With the typical engine running at about 35% efficiency, there is considerable waste heat be- tween the jacket water and the ex- haust that ElectraTherm converts into emissions-free/fuel-free electricity. ElectraTherm’s Green Machine gen- erator operates using a closed-loop ORC, where hot water is the fuel. Hot water from the engine enters a heat ex- changer to excite (pressurize) the non- flammable, nontoxic working fluid, driving the twin-screw expander and generator to create electricity. The company said its twin-screw ex- pander is unique in its configuration, lubrication and specifications, but the core technology is based on decades of proven compressor technology. The twin-screw expander has a rotational speed of 1800 to 4900PDF Image | DOD-funded ORC integration and replacement project
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