Combustion engines, such as those used in diesel generators or gensets, have seen extensive use across the globe for their reliable power generation capabilities. From diesel prime power for remote power generation to providing power for industrial processes, combustion engines have the ability generate anywhere from just a couple kilowatts to several megawatts of electricity. However even with huge leaps in technology, gensets typically lose over 50% of the their input energy to waste heat.
ElectraTherm’s organic Rankine cycle (ORC) solutions, the Power+ Generator and Active Cooler, are able to capture this waste heat – increasing efficiency and reducing energy costs. There are several other benefits you could also capitalize on such as reducing engine de-rate and selling excess electricity to the grid.
Factors That Make A Successful Application
The amount of heat available is a large factor in determining the amount of power that can be generated. Typically, heat sources above 100°C are considered the most practical. Along with this, the flow of water also plays a critical role. Find more information on the optimal conditions here.
The more time an application is up and running, the more waste heat there is available to convert into clean electricity. There are 8760 hours in a year and a suitable application experiences 80% up-time, whereas an ideal application experiences 95% up-time.
Cost of Power
Installing an ElectraTherm ORC heat to power system comes with several benefits, from reduced emissions to increased efficiency. However, the most tangible benefit often realized by customers is the value of electricity produced. The most successful applications have costs of electricity greater than $0.10/kWh.
Combined Heat and Power
By integrating ElectraTherm’s ORC products into your existing CHP system you improve both efficiency and your bottom line. After reducing the system’s cooling load and effectively generating clean electricity along with usable thermal, you will see why waste heat recovery is not only profitable, but practical.
The Power+ Generator was recently demonstrated with the U.S. Department of Defense, where it was used for remote power generation and was successfully able to act as a radiator replacement while increasing efficiency up to 10%. Read more about it here.
By utilizing your waste heat and reducing dependence from the grid, direct and indirect emissions are reduced. A fully utilized Power+ Generator on a diesel genset has the ability to reduce emissions by over 600 metric tons annually.
Energy Savings For Remote Power Generation
Three Power+ Generations were installed at a power station in Dutch Harbor, Alaska to convert the waste heat from diesel gensets into clean electricity. In remote areas such as these where cost of power is high, it is key to be as efficient as possible.
By using the Power+ Generators for waste heat recovery, the Alaska Energy Authority estimates $250,000 in annual energy savings. Additionally, thanks to the cooling effect the modules provide, one of the three radiators were eliminated – reducing electricity consumption by about 8,000 kW monthly and saving approximately 6,000 gallons of fuel annually.
Three Generators To Provide Additional 1,700 MWh Annually
ElectraTherm has been awarded a contract to provide a complete waste heat recovery system incorporating exhaust gas heat exchangers and three containerized 6500B+ heat to power generators complete with high efficiency coolers in order to take advantage of the waste heat on site.
By taking advantage of this excess heat, Pohnpei Utilities Corporation expects to produce an additional 1,700 MWh of additional clean electricity annually while reducing emissions by over 1,000 tons annually. Thanks to the scalable and mobile design of the system, future diesel generators can be integrated into the system to further utilize waste heat.
Additional 500 kWe From Twin Gas Turbines
In June 2014, ElectraTherm commissioned ten Power+ 4400s on a district heating system in Levice, Slovakia as a means of increasing onsite efficiency and generating clean energy for profit.
The installation utilizes the exhaust gas waste heat from two Rolls Royce gas turbines – run in parallel, the Power+ Generators are capable of generating approximately 500 kWe.
Increases Efficiency and Profits
By taking advantage of a resource you already have, our ORC solutions reduce the parasitic cooling load while providing additional horsepower – without affecting your existing processes. By increasing your site’s efficiency by up to 10%, you not only benefit from reduced energy costs and increased output, but could even qualify for local incentives that promote energy efficiency and sustainable advancements.
This additional power can be sold back to the grid for profit, used to offset energy costs, or simply used to increase overall power output.
Typical Energy Split in Combustion Engine
Both the engine and ElectraTherm module require cooling, satisfy both with one system. ElectraTherm’s integrated design combines both cooling duties into one radiator to provide 100% full-load cooling capability for the engine, independent of the module’s status.
ElectraTherm’s ORC solutions reduce the jacket water loop cooling load 70-100%, decreasing the temperature of the intercooler radiator. This cooling effect on the jacket water and intercooler temperature can significantly reduce engine de-rate in high temperature ambient conditions.
Pair this with the ability to act as a zero power consumption cooler that generates profitable power, it is no wonder why we call it the radiator with a payback.
Applications utilizing natural gases such as landfills capturing methane, waste water treatment plants, or biogas plants have another amazing waste heat recovery perk…
By capturing flare gas, ElectraTherm’s solutions can generate clean electricity while reducing or even eliminating flaring. This comes with several economic and environmental benefits plus you could even qualify for attractive incentives for reducing emissions.
Watch this video for an overview of flare elimination.