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2. THE COST ADVANTAGE OF USING AIR-CONDITIONING EQUIPMENT FOR POWER GENERATION Thanks to equipment standardization and high-volume production, air-conditioning and refrigeration equipment is available at a cost of around $ 200 - $ 300 per kW electric motor input. For example, the cost of a 1500 kW centrifugal chiller with a 300 kW electric motor varies, depending on options, from $ 60,000 to $ 90,000. The equipment cost of multi-megawatt conventional power generation equipment is an order of magnitude higher ($ 1,200 – 1,500 per kW generator output). Even higher cost is encountered for smaller (100 to 2000 kW) distributed power generation equipment. Reciprocating engines are the exception at $ 500 per kW, but these engines have emission problems and suffer from high maintenance costs. Industrial processes generate large amounts of waste heat. Waste-heat-driven steam power plants are often not economical, especially for capacities below 5 MW and for low-temperature waste- heat streams. In those cases waste heat power recovery has been attempted with Organic Rankine Cycle (ORC) machines. Due to high cost of the equipment, the penetration of this technology has been limited to specific niche markets such as geothermal. Moreover, most ORC applications have been heavily subsidized. The reason for high equipment cost is that current ORC systems utilize low-volume power equipment hardware. Waste heat power recovery systems are inherently limited in thermal efficiency due to the relatively low temperature of waste heat. Consequently, a waste heat power generating ORC system requires larger capacity components (boiler, condenser, turbine and pump) for equivalent power output than conventional fuel fired power generation equipment. This causes high overall system cost. Efforts to improve the ORC cost structure by focussing on thermal efficiency enhancements have not been successful in bringing the system cost down to a level that would allow a large market penetration. The absence of fuel cost means that the economically correct metric to be used for waste-heat power recovery systems is its cost per unit of power generating capacity ($/kWel). Better efficiency is only beneficial as far as it results in lower equipment/installation cost since the waste heat is free. 3. R-245fa, THE ENABLING REFRIGERANT FOR AIR-COOLED ORC SYSTEMS Given the lower cost structure of HVAC equipment versus power generating equipment, and the apparently good turbine action of the centrifugal compressor during power outages, it was decided to design an ORC system using HVAC hardware to the maximum extend possible. Only minor equipment modifications - not fundamentally affecting the equipment - were allowed. For example, modifying equipment to achieve higher cycle efficiency by going to higher boiler temperatures was only allowed if the resulting improvement in efficiency would result in a lower- cost overall product without too much additional development work. Air-conditioning equipment is only cost effective if it is used to its full design capability. Temperature/working fluid combinations that result in a turbine power output less than the power input of the existing compressor would not fully utilize the potential of this compressor hardware during turbine operation and would therefore result in higher equipment cost per unit power delivered. Conversely, temperature/working fluid combinations that result in a turbine power output higher than the power input of the corresponding compressor hardware would exceed the mechanical limits (e.g. gear and shaft torque limits and bearing loading limits) of the original compressor design. Modifications to overcome those limits were only allowed if the net cost per unit power delivered would reduce, again without too much additional development work. In order to preserve the cost advantage of the HVAC compressor as an ORC turbine it was found that the maximum temperature and pressure the turbine is seeing should be within the capabilities of the existing compressor housing. Moreover, to take full advantage of the given compressor hardware in turbine operation the power density of the turbine should be equal to that of the compressor. This allows unaltered use of the electrical and mechanical components of thePDF Image | Power Production from a Moderate Temp Geothermal Resource
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