DRD Power Ltd
Electric Power Generation from
Waste Heat Sources by
Organic Rankine Cycle
Clive Whitbourn CEng FIChemE
Roger Mallinson CEng FIChemE
22nd April 2010
New Ideas in Resource & Energy Efficiency - Peterlee
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2010
DRD
Background
o Energy & Resource Consultants
o Energy Mapping & Audits – Project
Identification
o Renewable & Sustainable Technologies
o Feasibility Studies
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2010
The Opportunity
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2010
Organic Rankine Cycle
Boiler
Expander
Waste
Heat
Electricity
Preheater
CW
Condenser
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2010
Benefits
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Electricity savings ~£100kpa (200kW)
CO2 savings = 700 tpa (200kW)
Payback ~3 years
Zero emissions
Fully automatic
No toxic substances
Use of non-flammable refrigerants with
low GWP
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2010
ORC Innovations
• Low temperature heat source, ie 90°C and
above
• Innovative use of a compressor as an
expander
• No intermediate heat transfer fluid
• Use of non-flammable refrigerants with low
GWP
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2010
Project Milestones
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Refrigerant Research - complete
Turbine Research - complete
Detailed Design - complete
Construction of 200kW Demonstration Unit
Commissioning and Operation – Q3. 2010
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2010
Refrigerant Research
•
Choice of refrigerant influenced by:
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Environmental & Safety factors
Engineering
Thermophysical factors
Commercial factors
Hydrocarbons, halogenated hydrocarbons,
and ammonia/water were examined
Both single component and mixed fluids were
considered
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2010
Turbine Research
• Ideally, use a mass-produced turbine for
reasons of cost and availability
• No mass-produced turbines available, so a
compressor run in reverse will be used
• Research identified any necessary
modifications eg lubricant flow
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2010
Modular Unit
Rated 200kWe ORC Unit
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2010
Seeking Early Adoption Sites
Waste heat sources >90°C
Typical examples:•
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Low Pressure Steam 1 – 2 tonne/hr
Process Vapours
Hot Water/Condensate 40 m3/hr (min)
Hot process streams requiring cooling
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2010
Potential for your Site
• Feasibility assessment
• Estimate of electricity produced
and value
• CO2 savings
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2010
Project Support
• Carbon Trust
• Shell Springboard award in February 2009
- innovation and carbon reduction
• NStar Finance
© Copyright DRD Power Limited
2010
DRD Power Ltd
Wilton Centre
Wilton
Redcar TS10 4RF
Tel: 01642 430090
info@drdconsultants.co.uk
Contacts:
Clive Whitbourn
Roger Mallinson
© Copyright DRD Power Limited
2010
Temperature/Enthalpy Chart
Temperature / Enthalpy Chart
180
160
liquid
vapour
pump
preheater
evaporator
superheater
turbine
condenser
heat source
heat sink
Turbine power
Temperature (deg C)
140
120
100
80
60
40
20
0
200
250
300
350
400
450
Enthalpy (kJ/kg)
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2010
500
550