Case Studies
For more reference sites and to see if your heat source is viable for ElectraTherm’s low temperature heat recovery systems,
please contact a sales representative.
PENDING INSTALLATION
Application: Flare Reduction
Location: United States
Power Output (Tested): 44 – 48 kWe
Scheduled for commissioning for Q3 2021, a single Power+ Generator will utilize the boiler process heat from one of three existing boilers to produce clean electricity in addition to reducing the emissions associated with flaring. With additional or larger units, the flaring could be eliminated permanently. This will be the first ORC application of its kind at a wastewater treatment plant in the world.
PENDING INSTALLATION
Application: Engine Waste Heat Recovery
Location: Pohnpei, Micronesia
Power Output (Tested): 200 – 225 kWe (3 units)
Scheduled for commissioning for Q3 2021, the site will be comprised of three containerized 6500B Power+ Generators. The waste heat recovery system will reduce emissions at the Nanpohnmal Power Plant and generate 1,700 MWh of clean electricity annually with the potential for more in the future.
Application: Engine Waste Heat Recovery
Pilot Installation (Net-Zero Cooling)
Location: Poland
Installed on a 800 kW engine at a biogas plant in Poland, the inaugural Active Cooler application incorporates a customized Power+ Generator with a high efficiency cooler to displace the previous radiator’s demand of 8 kW while generating an additional 35 kW, bringing the total net benefit to 43 kWe.
Application: Gas Compression Heat Recovery
Completed Demonstration (Net-Zero Cooling)
Location: United States
Commissioned at a gas compression station in Oklahoma, the ORC system provides zero-power consumption cooling while generating electricity. ElectraTherm’s ORC solutions are well suited for remote operation and micro-grid power generation.
Application: Air Compression Heat Recovery
Location: United States
Power Output: 45 kWe
Hot Water Temperature: 85°C (185°F)
Hot Water Flow Rate: 13 l/s (205 gpm)
Installed at a pharmaceutical facility in Virginia, a 4400B Power+ Generator runs in sync with a 500 kW water-cooled air compressor. The compression heat recovery system generates 45 kWe and runs 24/7, producing approximately 394 MWh annually. In addition to using the electricity generated to offset energy costs, the ORC process also reduces the parasitic cooling demand.
Application: Geothermal Heat Recovery
Location: Japan
Power Output: 60 kWe
Hot Water Temperature: 110°C (230°F)
Hot Water Flow Rate: 12 l/s (190 gpm)
This heat recovery application takes advantage of a community geothermal heating system for nearby homes. By capturing this excess heat, the residents receive the same benefits as before in addition to the production of electricity. Japan has attractive feed-in-tariffs for clean electricity, making this project particularly lucrative.
Application: Biomass Heat Recovery
Location: United Kingdom
Power Output: 130 kWe (2 units)
Hot Water Temperature: 115°C (240°F)
Hot Water Flow Rate: 10 l/s (160 gpm)
Novalux installed two 1.2 MW boilers (which consume approximately 4,000 tons of biomass waste per year) with two Power+ Generators to provide a combination of heat and power. This site exports $110,000 USD worth of clean electricity per year.
Application: Engine Waste Heat Recovery
Location: Germany
Power Output: 35 kWe
Thermal Input: 450 kWth
Installed at a biogas plant in rural Germany, this is the 41st biogas plant to be equipped with an ElectraTherm ORC. The plant processes over 45 tons of waste per day, enough to provide the machine with 450 kWth. The increased power output amounts to a 7% increase in total site energy efficiency.
Application: Engine Waste Heat Recovery
Location: Czech Republic
Power Output: 40 kWe
Thermal Input: 500 kWth
Running off a dual-stream of exhaust gas and jacket water waste heat, the low temperature ORC system is supplied with 500 kWth from two small gensets at a biogas plant where the system goes on to generate a combination of heat and power.
Application: Biomass Heat Recovery – CHP
Location: United Kingdom
Power Output: 60 kWe
Hot Water Temperature: 115°C (240°F)
Hot Water Flow Rate: 15 l/s (240 gpm)
The first 6500 series to be installed in the UK on an application of this nature, the unit was installed in early 2016 has ran 24/7 minus maintenance days. The Power+ Generator is used as a CHP unit, providing thermal for multiple purposes while generating electricity. The unit has generated upwards of 2,000,000 kWe and the distributed thermal saves the owner approximately $90,000 USD annually from reduced fossil fuel consumption.
Application: Biomass Heat Recovery – CHP
Location: United States
Power Output: 35 kWe
Hot Water Temperature: 90°C (195°F)
In a collaboration with Wisewood Energy, ElectraTherm installed a biomass heat recovery system designed for combined heat and power. The ORC is fueled by hot water routed from the boiler burning woody biomass. In addition to generating electricity and disposing of waste, the system provides heat for the nearby public health building as well as for the power site.
Application: Engine Waste Heat Recovery
Location: United States
Power Output: 85 kWe (3 units)
Three Power+ Generators run parallel to three diesel gensets at a remote power station in Dutch Harbor, Alaska. This ORC units increase total system efficiency up to 8% in addition to reducing the cooling load significantly enough to act as a radiator alternative for one of the gensets – completely offsetting the cooling load. The City of Unalaska estimates approximately $250,000 in annual energy savings.
Application: Engine Waste Heat Recovery
Location: United States
Power Output + Load Offset: 110 kWe
In collaboration with the U.S. Department of Defense, ElectraTherm developed an integrated ORC system to provide full-load cooling for the engine while generating additional power. Representatives from Southern Research concluded that the reduction in fuel consumption along with the offset cooling load in addition to the power generated amounts to a 10% increase in efficiency.
Application: Geothermal Heat Recovery
Location: United States
Power Output: 55 kWe
Hot Water Temperature: 110°C (230°F)
Hot Water Flow Rate: 9.5 l/s (150 gpm)
In collaboration with the U.S. Department of Energy and Jipangu International, ElectraTherm installed a fully-packaged ORC system designed for unattended operation at a remote mine in Nevada.