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D APPENDIX D: TECHNOLOGY SOLUTIONS FOR ENERGY RECOVERY D. Microturbines Microturbines are high-speed devices, usually rotating over 40,000 rpm. They come in several physical configurations, which represent tradeoffs in cost and performance. The engine can be a single-shaft machine, which reduces cost, or a split-shaft machine, which is more complex but allows for direct drive of a generator, thus avoiding the need of an inverter. Another design consideration is choice of bearings. Air bearings, which have emerged as a technology of choice, reduce the cost of the microturbine, but oil bearings offer longer life and are more rugged. The simple-cycle microturbine is less efficient than a recuperated and/or intercooled machine, and is also less expensive. Simple cycle microturbines are projected to have an efficiency of 26-30%; but, with heat recovery, the efficiency could approach 40%. When used in a cogeneration or combined heat and power (CHP) system, the fuel conversion efficiency can approach 80%. Microturbines could play a large roll in manufacturing because they can be deployed to generate a portion of a plant’s electricity needs onsite, reduce demand during peak periods, and support premium power applications (e.g., microelectronics manufacturing). Microturbines are even more efficient when operated as part of a CHP system, which can meet some of the facility’s thermal requirements as well. However, microturbines will have to compete with reciprocating engines and fuel cells to gain a stronghold in this market. One of the promises of microturbines is greater reliability and a lower operating cost than reciprocating engines. However, field experience with microturbines has been limited, and because the technology is evolving rapidly, reliable information about performance is not readily available. Another area in need of improvement is environmental emissions, in particular NOx. While manufacturers have raised hopes that microturbine emissions would be much lower than emissions from other technologies, current rates are similar to those for low-emissions gas engines. Current projections for operating costs are for $90 per kWyear, falling to $75 by 2020. These compare favorably with reciprocating engines today and appear even more attractive in the future. Realizing these performance goals require further product development with deployment of advanced materials and operating experience. 114PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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