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• Reducing the plant cost relative to the original PureCycle ORC plant by incorporating and qualifying more commercially available components made feasible by the lower operating temperature in geothermal applications. • Develop control algorithms and methods for operation with tube and shell heat exchangers rather than the fin-tube technology applied in the original PureCycle plant. The geothermal plant modules were designed and qualified at the United Technologies Research Center before installation at Chena Hot Springs. Cycle analysis showed that with 1060 gpm of 164 °F temperature geothermal liquid as the heat source and virtually unlimited 40-45 oF water (at least during the summer months) from a shallow infiltration well as heat sink, two geothermal power plants could be installed using HFC134a as the working fluid. The first unit (ORC1) was installed in August 2006, and the second unit (ORC2) a few months later in December. Both operate under the same design points with the exception that ORC2 is dual air and water cooled to take advantage of the cold ambient winter temperatures in interior Alaska. A picture of the two modules installed at Chena is show in Figure 2. Each power plant module has been operating at the following design conditions: Water Design Points Heat source: Tin = 164 °F Heat sink: Tin = 40 °F Refrigerant Design Points Mass flow rate: Evaporator/turbine inlet pressure: Condenser/turbine exit pressure: Turbine gross power: Pump power: System output power (net): Thermal efficiency: Tout = 135 °F Flow rate: 530 gpm Tout = 49 °F Flow rate: 1614 gpm This efficiency was a challenge given the limited thermodynamic availability of the low temperature geothermal heat source. A completely reversible thermodynamic cycle working with the same heat source and heat sink temperature glides would have a thermal efficiency just under 18% (Figure 3). Fortunately, efficiency improvements are far less critical in power generation when the fuel is essentially free. Instead, the important factor is overall utilization of the geothermal fluid, and so minimizing flow rate of water through the evaporator is critical in system design. COOLING SUPPLY FOR CONDENSERS (WATER AND AIR) To maximize system performance and take advantage of the excellent cold water resources available locally, the first ORC module was designed to be water cooled at 40-45 oF. In order to maximize net power production, a water supply system was designed which would require no pumping load. This was accomplished by employing a low tech siphon to ‘pull’ water out of a shallow, large diameter well located 2700 ft to the east of the power plant. The elevation difference of +33 ft between the cold water well and the power plant allows 1500 gpm to flow through each condenser at 5 psi without a pump. To minimize pressure loss due to friction in the 3 26.8 lbm/s 232 psia 63.6 psia 250 kW 40 kW 210 kW 8.2 %PDF Image | Chena Hot Springs 400kW Geothermal Power Plant
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