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Chena Hot Springs 400kW Geothermal Power Plant

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Chena Hot Springs 400kW Geothermal Power Plant ( chena-hot-springs-400kw-geothermal-power-plant )

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heating (Davis, 2007). This is much higher than the national average of 6.8% as estimated by the Bureau of Labor Statistics. Chena Hot Springs Resort, located 60 miles northeast of Fairbanks Alaska, is no exception to this rule. Prior to the installation of the geothermal power plant facility, power was generated from a 400kW diesel recip. The cost for generating power in 2006 was 30¢ per kWhr, which at an average load of 230kW represented a cost of $604,000 in 2005. The fuel cost represented approximately 60% of this expense, or $362,400. Two well-known manufacturers of binary ORC systems for geothermal applications were approached in 2002 and 2003 about designing a system for Chena Hot Springs. One manufacturer declined the opportunity due to the low resource temperature, and the second manufacturer was more than willing to build a one of a kind system for Chena, however the cost per kW output would be very high. In 2004, Chena Hot Springs was presented with a new opportunity of working with United Technologies Corporation (UTC) to demonstrate their existing PureCycle technology on the geothermal resource at Chena. UTC was awarded funding from the Department of Energy to complete design work on the system, and the power plant modules were designed, assembled, and tested at UTRC in Hartford, Connecticut beginning in late 2004. The first unit (ORC1) underwent 1000 hours of qualification testing before being disassembled and shipped to Chena Hot Springs. The second unit (ORC2) was partially assembled but not tested before being sent to Chena several months later. CHENA POWER PLANT DESIGN The PureCycle 200 platform that the Chena plant is based on was designed to produce 200kW of electric power from waste hot gas sources between 500 and 1000°F using mass-produced Carrier chiller components. The most critical components include a single-stage centrifugal compressor which runs in reverse as a radial inflow turbine to produce 200kW of power, and heat exchangers originally designed for large chiller applications. Additionally, local and remote monitoring and control was applied for both operation and data collection. The specific objective of the Chena project was to demonstrate the low cost of the power generation equipment ($1350/kWhr installed) and the feasibility of producing electricity at a cost of less than 5¢/kWh from a 165°F geothermal resource with 98% availability. The geothermal application for the PureCycle platform involved some additional innovation and opportunities for cost reduction beyond that of the original PureCycle 200 platform, including: • Changing the working fluid used in the PureCycle ORC plant from R245fa to R134a. This fluid is a better match for low temperature geothermal applications and enables a significant cost reduction, both directly because R134a is a low cost fluid widely used in HVAC equipment and indirectly by allowing lower cost commercially available components to be used in the power plant. • Developing low cost heat exchangers specific to geothermal applications based on designs and production capability in place for Carrier’s large commercial and marine water-cooled chillers. 2

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