The DirectGen. Clean, Renewable Power From High-Pressure Steam. AERCO.com

Transcription

1 The DirectGen Clean, Renewable Power From High-Pressure Steam AERCO.com

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3 Index Turning Waste Steam into Usable Power Page 4 Operating Characteristics of the DirectGen Power Plant Page 5 Environmental Stewards Page 6 Features and Benefits Page 7 Working Principle Page 8 DirectGen System Components Page 9 DirectGen Applications Pages DirectGen System Design Guidelines Page 18 Dual Expander Part Identification Diagram Example Page 19 Technical Data Pages Model Nomenclature Page 22 DirectGen Site Investigation Form Page 23 Engineering Guide Specifications Page

4 Turning Waste Steam into Usable Power What is Energy Recovery? Energy recovery is the method of using the highpressure steam or waste heat of one process as the input that powers the next process. Using this high-pressure steam, energy recovery creates clean, usable heat or electricity from something that would have otherwise been thrown away into the atmosphere or dumped into rivers and lakes. Why Should You Care? Today, only 6% of energy is recovered from the exhaust of industries throughout the United States. That s a tremendous amount of energy being discarded and a vast, underutilized resource that is available now and ready to be tapped into. With energy losses of $6 billion per year, energy recovery is the #1 savings opportunity for industries to capitalize on. Energy recovery: Saves the environment by creating clean power from a renewable energy source that doesn t produce toxic emissions or put dangerous pollutants into the world. Saves you money by decreasing your dependence on burning fossil fuels to power your business, which in turn reduces your energy bills overall and also enables you to reinvest those savings back into your enterprise. The DirectGen AERCO s DirectGen is able to capture and turn high-pressure steam into clean, usable electrical power. DirectGen can be used in a variety of applications including Industrial processes (e.g., manufacturing, bottling, molding), commercial buildings with large central steam plants including universities and hospitals, as well as high-pressure natural gas lines. It can be used in any process that uses a pressure reducing valve. Instead of burning fossil fuels, the DirectGen generates power using high-pressure steam in a continuous, closed loop, so it s fossil fuel-free and emission-free. Saving energy by not burning additional fossil fuels translates directly into saving money ROI is typically within two to four years. Why AERCO? Nearly 30 years ago, AERCO revolutionized the industry by creating condensing boilers that recover and use latent heat and energy from the unit itself to increase its own efficiency, save energy, and reduce fuel emissions. With the DirectGen, AERCO takes this technology to the next level by not only providing reliable product solutions, but also energy saving solutions on a more profound scale giving you significant ROI for your entire enterprise. We ll help put money back into your pockets and your business instead of letting it disappear up the smokestack. *estimated by the Energy Information Agency 4

5 Operating Characteristics of the DirectGen Power Plant Converting High-Pressure Steam into Clean Power High Pressure Electrical Power DirectGen Pressure Regulator Low Pressure 1. High-pressure steam is reduced in pressure through the DirectGen s twin screw expander 2. DirectGen converts this useful energy directly into power which can be used back in the commercial process itself or returned to the power grid Industrial Process: Bottling Molding Manufacturing Commercial building: Office/University Hospital Natural Gas Lines Advantages of a Screw Expander vs. Turbine Most energy recovery products that incorporate DirectGen technology use a turbine expander. The DirectGen uses a twin-screw expander which provides better overall performance, higher average efficiency and a faster ROI: Performance Parameter Heat Conditions Operation Efficiency Maintenance Applications Turbine Technology Requires superheat condition for reliable operation. Turbine runs at very high speeds (>15000 rpm) and is susceptible to liquid-drop, blade erosion. Under design conditions 70-90%; Under changing conditions significant drop in efficiency or shut down due to changes in thermal input. High maintenance cost with highly-technical maintenance service team. Power plants, high-quality residual heat generation. Screw Expander Superheat not required. Can be used with superheated vapor or saturated vapor. Relatively low speed (<3600 rpm), insensitive to liquid drop ingestion. Under design conditions 70-88%; under changing conditions slight drop in efficiency no instabilities due to changing thermal input. Expected 10-year before first major service call. Filter maintenance. Low-quality residual heat, renewable energy sources. The DirectGen s Twin-Screw Expander vs. Other Screw Expanders The DirectGen s screw expander is the best in the marketplace. It delivers 8-10% higher efficiency than other screw expanders available reaching up to 90% isentropic efficiency. It also provides the greatest turndown operating to 5% of nominal power, and delivers the widest operating range of between 55kW to 5MW. 5

6 Environmental Stewards Due to its inherent capability of creating new, clean power out of something that would have been thrown away into the environment, the DirectGen is especially eco-friendly. It not only increases your plant s efficiency and puts money back into your pocket, but also reduces your reliance on fossil fuels which is good for your business and good for the environment. Fossil Fuel-Free AND Emission-Free The DirectGen is self-operating and doesn t burn expensive fossil fuels. Because it works in a continuous, closed loop system, it doesn t give off any carbon emissions or undesirable pollutants. Develops the Distributed Power Network Through creating an auxiliary source of power that does not come from a power grid, the DirectGen helps develop the distributed power network. By allowing users to consume supplemental, non-grid power locally, the DirectGen helps to decrease both peak and overall power demand on the utility grid while also reducing utility rates. Produces a Negative Carbon Footprint! By lowering pressure on the overall power grid, the DirectGen helps decrease dependence on burning fossil fuels which in turn lessens the need to build more power plants. Fewer power plants mean less carbon emissions and a smaller carbon footprint. By producing clean power and reducing our dependence on burning fossil fuels for electricity, the DirectGen not only reduces carbon footprint, it produces a negative one! 6

7 Features and Benefits Using high-pressure steam and AERCO s innovative twin-screw expander the DirectGen is able to create clean power for a variety of applications. Its power output ranges from 55kW to 5MW and can be combined to generate higher output plants. With payback within two to four years, you can t afford not to incorporate one into your enterprise. Clean, Renewable Power with No Carbon Footprint Clean power generation from high pressure (>15 psig)steam sources from a variety of applications including: - Industrial plants - High pressure natural gas lines - Large central steam plants - Any process that uses a pressure reducing valve Power output ranging from 55kW to 5MW No fossil-fuels consumed No toxic emissions produced (steam can be condensed or released to atmosphere) Modular and scalable to accommodate larger plants Significant Savings ROI in 2-4 years! Very low operating and maintenance costs (system is self-powered and completely automated no operator) Substantial state and federal rebates available Operational Advantages High reliability 20-year design life with robust components (low mechanical stress = long life) Uses the most efficient screw expander available in the marketplace instead of a turbine to provide greater flexibility with varying input loads, increased reliability and the widest operating range Maintains good efficiency even at partial load Highest turn-down available: 5% of nominal power Operates 24 hours a day, 7 days a week, 365 days a year providing continual power (other renewable sources like the wind or sun are not always present) Turnkey package the entire unit is prepackaged and comes on a single skid module or multiple modules depending on system size We customize to site conditions, and take care of installation and start-up to ensure performance is optimized Considerable utility cost savings and decreased rates due to the DirectGen reducing peak demand 7

8 Working Principle Steam screw expanders convert heat into power using basic thermodynamic principles. Steam (saturated, superheated or wet steam) acts as a media for the expander. When high pressure steam (point 1) enters the expander, the expansion process drives a pair of twin screws. A generator is either direct coupled or connected via a gear box to one of the shafts of the twin screw pair, thereby producing power. This expansion process expands the steam to a lower temperature and pressure (point 2). ORC screw expander - ORC power plant using latent heat input from steam. Customer can use the remaining steam in their manufacturing process. Steam Screw Expander Working Conditions Saturated or superheated vapor, wet steam with differential pressures of at least 1.5 bar or 21.8 psi. The steam screw expander is an open-loop type. During the periods when steam enters the expander to when it exits the expander, the quantity of steam will be maintained and the same quantity can be used in the next step of the process or released to atmosphere. Energy which is lost through a Pressure Reducing Valve (PRV) can now be converted to electric power by the steam screw expander. There are two types of DirectGen Systems: Back pressure and a Condensing type. The choice between these two DirectGen Screw Expander systems depends on the process heat requirements for the application. Low pressure steam at the exhaust port of the DirectGen Screw Expander can be used in the following ways: Low pressure steam screw expander power module second stage expansion. 8

9 DirectGen System Components Waste Steam Dual DirectGen Application Fig X: 1.5MW DirectGen Dual-Steam Screw Expander System Melbourne, AR The key components of the DirectGen System are: Power Module comprised of the screw expander and power generator The screw expander is coupled directly to the generator shaft. Oil Station the oil station steam side of system). stores the required lubricant to be pumped to the expander (isolated from Steam Separators the steam separator eliminates excess water vapor from steam, increasing the overall thermal efficiency of the high pressure gas. Steam Surface Condenser the steam that exits each screw expander is condensed by passing through the water cooled surface steam condenser 9

10 Applications Many customers have a wide variety of thermal needs at their facilities whether for sterilization, process heating, drying/curing, etc. These needs may include high pressure steam energy, low pressure steam or hot water. Typically customers have no idea what steam energy costs them, but are keenly aware of their fuel bills. The end result tends to be a focus on fuel expenses and not efficiency or reliability. Petroleum Industry, Chemical Industry and Petroleum Production Industry Steam is a principle energy source for chemical industrial processes. It provides energy for process heating, pressure control, mechanical drives, and component separation, and is also a source of water for many industrial operations and chemical reactions. The popularity of steam as an energy source stems from its many advantages, which include low toxicity, transportability, High-efficiency, high heat capacity, and low production costs relative to other energy transport mediums. Natural gas is the dominant fuel source of process steam systems. Due to the increased volatility of the fossil fuel market, energy efficiency measures must be taken to ensure steam remains an economically favorable energy source in the future. During the production process, large amounts of pressurized waste steam is generated and released to the atmosphere. This high pressure steam can be piped to the screw expander to generate power. Prior to releasing high pressure steam to the atmosphere, it is typically reduced with a pressure reducing valve (where energy loss is incurred), which can be replaced with a steam screw expander converting steam pressure to power. The steam screw expander can accept a pressure range from 1.5 to 31bar(A) or 21.8 to psi. A single steam screw expander can generate up to 3MW of electrical power output at 48 t/h of saturated steam. 10

11 Applications The most commonly used system for power generation from waste heat involves using the hot exhaust stream to generate steam in a waste heat boiler, which can then drive a screw expander. Heat recovery boilers/screw expander systems operate thermodynamically as a Rankine Cycle, as shown in the diagram below. High Pressure Steam Hot Exhaust Stream Heat Recovery Boiler Pump Generator Power Out Condenser Screw Expander Heat Out In the steam Rankine cycle, the working fluid water is first pumped to elevated pressure before entering a heat recovery boiler. The pressurized water is vaporized by the hot exhaust and then expanded to lower temperature and pressure in a screw expander, generating mechanical power that drives an electric generator. The low-pressure steam is then exhausted to a condenser at partial vacuum conditions, where heat is removed by condensing the vapor back into a liquid. The condensate from the condenser is then returned to the pump and the cycle continues. Steam heat recovery systems are the most familiar in the industry and are generally economically preferable, as the heat stream temperature exceeds 800 F in many cases. 11

12 Applications Industrial Boilers Steam is critical to several manufacturing sectors, and it is estimated that approximately 43,000 industrial boilers consume about 6,500 TBtu of fuel annually. Fuel consumption for steam generation is greatest in the chemicals, refining, food, paper, and primary metals industries where steam generation can account for anywhere from 10 to 80% of total energy consumption. Total unrecovered heat from industrial boiler exhaust gases is estimated at about 1,200 TBtu/yr. The most significant fuel sources for boilers are natural gas and byproduct fuels. Exhaust temperatures for industrial boilers depends on the required steam pressure for a given industrial process. Heat recovery is quite common for boilers. Options include economizers, air preheaters, or both. Average exhaust temperatures from boiler economizers using conventional fuels are likely to be around 300 F. Though there are a large number of small boilers in different facilities, total U.S. industrial boiler capacity is dominated by boilers with energy consumption greater than 50 million Btu/hr. the use of economizers can be considered a fairly typical practice. The work potential of this waste heat source is about 400 TBtu, which considerably exceeds the work potential of waste heat exhausted by other higher temperature sources. Considering the large number of industrial boilers (43,000) and the high quantity of energy consumed for steam generation, incremental improvements in boiler efficiency could have an appreciable impact on total energy consumption. It should also be noted that commercial boilers are also significant energy consumers, responsible for another 1,630 TBtu/yr of energy consumption, and responsible for 263 TBtu/yr of low temperature waste heat loss. Industrial processes that produce these temperatures include calcining (indirect kiln) operations (cement, lime, alumina, and petroleum coke), metal melting, glass melting, petroleum fluid heaters, thermal oxidizers, and exothermic synthesis processes. Key Waste Heat to Power (WHP) opportunities within these operations are provided below: Metals Metal manufacturing involves a large number of high-temperature processes from which waste heat can be recovered. Steel mills, for example, have various high-temperature heat- recovery opportunities. In integrated mills, waste heat can be recovered from coke ovens, blast furnaces for iron production, and basic oxygen furnaces for steel production. There are also opportunities to recover waste heat from electric arc furnaces. Brass foundries have a variety of waste heat sources, such as melting furnace exhaust, ladle preheating, core baking, pouring, shot-blasting, castings cooling, heat treating, and quenching. 12

13 Applications Oil and Gas Production There are a number of flared energy sources in oil and gas production that could utilize the waste heat to generate steam or hot water and then electricity via the DirectGen or OriGen Power producing systems. Petroleum Refining Basic processes used in petroleum refineries include distillation (fractionation), thermal cracking, catalytic, and treatment. These processes use large amounts of energy, and many involve exothermic reactions that also produce heat. Modern refineries are highly integrated systems that recover heat from one process to use in other processes. However, many operations still release high-quality waste heat that could be recovered for power production. An example is the exhaust from petroleum coke calciners. Petroleum coke is heated to 2,400 F and the exhaust is typically 900 to 1,000 F leaving the calciner. Natural Gas Compressor Stations There are many opportunities at natural gas compressor stations in North America. These systems generate substantial heat from gas powered engine/compressors that can be recovered to generate steam for the DirectGen system or hot water for the OriGen (ORC) system. Landfill Gas Energy Systems Landfills that use reciprocating internal combustion engines or turbines to produce power could generate additional power with waste heat boilers or economizers using the 800 F+ hot exhaust gases to generate steam or hot water. Chemical Industry There are several major segments of the industry, including petrochemicals, industrial gases, alkaline and chlorine, cyclic crudes and intermediates (e.g., ethylene, propylene, and benzene/ toluene/ xylene), plastics materials, synthetic rubber, synthetic organic fibers, and agricultural chemicals (fertilizers and pesticides), in which hightemperature exhaust is released that could be recovered for power generation. 13

14 Applications Two-Stage Design Increases Energy Recovery and Improves Efficiency Depending on the waste heat characteristics of any application, the DirectGen Steam Expander can work in series with the OriGen (ORC) Screw Expander System. The DirectGen utilizes the steam pressure differential, while the OriGen recovers the latent heat of vaporization to generate power, whereas the latent heat from condensed steam in a steam turbine system is wasted. DirectGen (Steam) OriGen (ORC) Steam Screw Expander Steam Boiler Generator Pump Steam In R245fa Condenser Side Heat Exchanger Water Out Evaporator Side Pump Generator Condenser ORC Screw Expander 14

15 Applications Waste-Wood to Energy Application There is a staggering amount of waste when producing wood products around the globe. Manufacturers of these products are burdened with the removal of waste wood from their property and the costs that go with it. The easiest way to turn sawdust, wood-chips or waste wood into energy is to burn it something that lumber, pulp and paper companies have been doing in their mills for a long time. Pound for pound, scrap wood contains about 40 to 50 % as much energy as coal, but that s plenty of energy potential from a wood burning combustor/boiler plant to generate the required high pressure steam to spin the gears in a screw expander and generate electricity. The DirectGen power plant can accept clean high pressure steam from a solid fuel combustor/boiler and produce reliable electricity. For manufacturers, this presents two major advantages; the removal of large amounts of waste wood and the production of electricity to be used on site or sold back to the grid. The Heat Output Value of Waste Wood All combustible materials have a heating value normally expressed as gross calorific or higher heating value. This heating value is a function of the thermal energy that can be obtained by burning one unit mass of the material. Unprocessed wood that is bone dry is accepted as having an average calorific value of approximately 8500 Btu/lb. However, both factors described above, namely moisture content and particle/physical size, have a significant effect on the realizable thermal potential of wood waste. The maximum thermal potential of waste wood can be obtained with an integrated combustion system as mentioned above. The combustors are designed to extract and deliver the thermal potential as efficiently as possible. An accurate analysis of wood waste materials to identify its gross heating value must take into account the following factors. The heat content per unit of waste according to its moisture content The efficiency of the energy conversion process utilizing a solid fuel combustor to generate steam Impacts of Moisture Content in Waste Wood Shown in the table below, high moisture content in wood waste has the direct effect of lowering the as-fired value of the waste as well as detrimentally affecting the overall combustion efficiency. This occurs due to the large amount of energy required to heat significant quantities of excess air and to vaporize the moisture in the wood waste, which together with the moisture formed as part of the thermochemical combustion process itself, is lost as latent heat when vented to the atmosphere. The moisture content of waste wood can vary considerably depending on the manufacturing process - such as an induced drying process. For example, sanding dust from plywood and particleboard manufacturers following the drying and hot pressing stages, at which point moisture content can be lower than 10%. Fuel Waste Wood Waste Wood Heat Value based on Moisture Content (%MC) As Fired Gross Calorific Value Btu/lb Typical Burner Efficiency (%) Usable Net Heating Value Btu/lb

16 Applications 16 Waste Heat Recovery: Glass Manufacturing Industry A staggering amount of energy is required for the production of glass. Although the industry has now become relatively efficient in its primary production processes, there is still great energy potential being lost. Much better use could be made of this wasted energy. Waste heat recovery in the glass production industry will result in large savings in energy costs. By utilizing waste heat recovery equipment, it is possible to use the high temperature exhausted waste heat for electricity, steam generation, and heating. Glass production companies may use the generated energy itself, or feed the electrical grid. The glass industry consumes approximately 300 TBtu/yr, and some sources estimate that as much as 70% of this energy consumption is devoted to glass melting and refining processes in high temperature furnaces. Furnaces vary widely in the energy required to melt a ton of glass. The theoretical minimum energy for melting glass is only about 2.2 million Btu per ton. However, some furnaces consume up to 20 million Btu/ton. Furnaces used in large glass melting operations include direct-fired, recuperative, regenerative, unit melters, oxy-fuel, and mixed fuel furnaces. In the United States, more than half of all glass furnaces are natural gas-fired regenerative furnaces, which account for over 90% of the tonnage produced. Best practice furnaces have efficiencies of about 40%, with stack heat losses about 30% and structural losses accounting for another 30%. Regenerators and recuperators are the most frequently used systems for waste heat recovery in the glass industry. Glass melting is a high temperature operation providing several opportunities for recovery of high grade waste heat. Without heat recovery, stack exhaust temperatures typically exceed 2,400 F [1,315 C]. Recuperators and regenerators for combustion air preheating are the most common methods for waste heat recovery. The installation of a waste heat recovery boiler in-line with the exhaust heat stack can generate steam to be piped directly to the DirectGen Steam Expander to generate power. The generated electricity can be used on-site in the glass production process and the glass manufacturers can save the expensive procurement of this power in the market. All possibilities implicate cost savings and CO 2- savings. The priority is always to reduce the glass manufacturer energy consumption, while also making their requirement and energy costs more predictable. This provides greater planning security for the overall production process. Hot flue gasses discharging into the atmosphere is essentially unexploited waste heat. The key is to take the large volume of waste heat which leaves the factory virtually unused and turn it into usable energy. The priority is always to reduce the client's existing natural gas or electricity consumption, while also making their energy requirement and energy costs more foreseeable. The technical principle behind all of this is relatively simple to install a waste heat recovery boiler in the exhaust gas stream. In the waste heat boiler, hot air is converted to usable energy such as steam. The outcome of waste heat energy recovery: Depending on the site conditions, companies can expect to save hundreds of thousands of dollars each year in energy costs, and thousands of tons of CO 2. AERCO s Energy Recovery team can take the information provided on the site survey form (see page 23) and provide a power output and equipment price estimate.

17 Applications Waste Heat Boilers (WHB) Depending on the application, a waste heat boiler may be considered. A waste heat boiler would be used to generate large quantities of high-pressure saturated steam. Pumping steam directly to the screw expander is a very efficient method of generating power. A waste heat boiler is a recovery type steam boiler that is not equipped with a hearth, since the water is not heated by combustion inside the boiler, but through the recovery of heat from fumes from the exhaust stack, which can come from various sources. This allows the recovery of thermal energy, which before was discharged to atmosphere, and thus classifies the WHB boiler among the most advanced tools to increase the energy efficiency of a glass production facility. The boiler can be single or double pass. In the case of double pass boilers, the fumes inlet and outlet are on the same side of the boiler and the rear part is equipped with adequately sized reversing chamber to ensure a correct inversion of the fumes. Waste Heat Boilers, Courtesy of ICI Caldaie 17

18 DirectGen System Design Guidelines DirectGen Steam Expander systems are typically used in four major steam generating applications: Forest Products, Chemical Manufacturing, Glass Manufacturing and Petroleum Refining. A preliminary DirectGen pre-design usually requires the available heat source to be evaluated and usually involves visiting the site and collecting information (See page 23 in this catalog for the site investigation form). The geographic location of the system needs to be considered as average annual wet bulb temperatures affect the size of the condenser used on the DirectGen system. The size and efficiency of the DirectGen system is based on the quality and quantity of the available heat source. The below guidelines will help with developing the actual net kw output of the DirectGen. Steam quality is an important characteristic. In thermodynamic terms, quality is used to define how much vapor, by mass, is in a vapor/liquid mixture. The steam boiler or steam generator induces energy to the boiler water; phase change occurs (steam is generated) and the state of the water moves to the right from point A toward point B at constant temperature, see graph below. After the steam has reached point B, any increase in the steam energy is known as superheat. When energy is extracted from the steam at point B (phase change back to the liquid) the steam travels back toward point A on the curve below. Temperature / Pressure Constant Temperature Energy / Unit Mass DirectGen Design Guidelines The use of heat recovery devices to produce steam is normally an economically sound investment, but all situations should be evaluated on a case by case basis. Typical heat recovery devices include: waste heat recovery boilers (WHRB), heat recovery steam generators (HRSG), recuperators, super heaters, and economizers. Forest Products, a manufacturer of wood products, has a heat resource for the DirectGen system of waste steam from a combuster burning waste wood pulp. There are minimal special requirements for this heat resource, as the steam would otherwise be vented to atmosphere. It is important not to under-size the DirectGen system and utilize the maximize amount of waste heat available. 18

19 Dual Expander Part Identification Diagram Example DirectGen Dual Expander - Part Identification Diagram (PID) The diagram above shows a dual expander system coupled to a single power generator. Due to the significant amount of high pressure steam, it was necessary to design the system with two expanders. 19

20 Technical Data Typical Wiring Diagram for DirectGen Systems Customer Supplied Power, Supply to DirectGen Generator A1 B1 C1 Pe(N) I_35 A1 B1 C1 Pe(N) Power Supply to other internal components QF11 250A Generator Breaker RV 95mm 2 A1 B1 C1 1L1+ ON FU11 FU12 RV 1.0mm 2 WM11.1 WM11.2 WM11.3 WM11 V1 V2 V3 VN Twisted-pair Cable TE B A Communicate with PLC (Modbus Protocol) CT11 400/5A CT12 400/5A Current Transformers Generator Grid Contactor P2 S1 P1 S2 P2 P1 S1 S2 P2 P1 S1 S2 CT13 400/5A CT11.1 CT11.2 CT12.1 CT12.2 CT13.1 CT13.2 BS11.8 S1 S2 S1 S2 S1 S DMG700 A1 A2 Power Meter L01_3 N01_3 Power Supply AC 220V, 60Hz KM11 250A In Cabinet On Site Power Generator Gen I_36 1L1+ BS11 MACX 7 8 MCR-SL-CAC Current Transmitter 4 5 I11 COM11 H KM11 System ON Indicator Light 2M 2L2+ 20

21 Technical Data DirectGen Screw Expander Saturated Steam Mass Flow Rates This page intentionally left blank. 21

22 Model Nomenclature DSG 1 XXXX YY SYN ST 4160 Y E Model ORG - OriGen DSG - DirectGen Design Series 1 = 1 st Design 2 = 2 nd Design 3 = 3 rd Design 4 = 4 th Design Unit Size kwe kwe kwe kwe kwe kwe kwe xxxx - Custom Size Warranty Options S = Standard Warranty E = 5 year Expander 5 = 5 year Complete Unit Reactive Power Compensation Module Y = Yes N = No (feature on units over 1000 kw) Output Voltage 0460 = 460V / 3ph / 60hz 4160 = 4160V / 3ph / 60hz Heat Source HW = Hot Water ST = Steam OL = Hot Oil Heat Exchanger EV = Evaporative Condensers WC = Water Cooled AC = Air Cooled HY = Hybrid YY = None Generator Type IND = Induction SYN = Synchronous Condensing Temperature 89 = Design Condensing Temperature in ºF xx = Based on Ambient Temperature Evaporator Temperature 230 = Standard Evaporator Temperature xxx = Custom 22

23 DirectGen Site Investigation Form Project Contact Information Company Name: Address: City/State/Zip: / / Contact Person: Phone: Project Description Manufacturing Water Treatment Power Generation Chemical Industry Petroleum Industry Food and Beverage Ceramics / Glass Industry Water Treatment University or Institutional Landfill / Waste Disposal Other Location: AERCO Representative Contact Person: Phone: Date: Available Heat Source Steam - high pressure Exhaust gas - stack Steam - low pressure Geothermal (well, hot rocks) Waste water from process Solar hot water (>170 F) equipment (> 170 F) Hot oil Other Mechanical Equipment Space Indoor application Outdoor application Length x width Steam Heat Recovery Application Steam pressure PSI Waste Water Heat Recovery Application Available fluid temperature (min 170 F, if process water, list available source and return temperature) F Supply water temperature F Return water temperature F Fluid flow of water source GPM Is water source continuous flow (24/7)? Yes No, please specify days and hours Fluid pressure PSI Fluid ph Water Composition Clean Organic compounds Glycol % Sulfur Grey water Other Is superheat available? No Yes Lbs/hr or boiler horse power Is the waste steam source continuous flow (24/7)? No Yes DewPoint of waste heat F Exhaust Gas Heat Recovery Information What fuel is used for exhaust stack: Natural gas Diesel Methane Other Lb/hr Temperature of exhaust gas F Is condensing of exhaust gas allowed by a heat exchanger? Does exhaust source have dust particulate matter? (If yes, please specify any details, such as quantity, dry/wet, abrasive): No Yes Electrical Rate Information Combined electric rate $/kw Base electric rate $/kw Demand charge $/kw Local annual average ambient temperature F Local average wet-bulb annual ambient temperature F Design economics for average ambient temperature or peak ambient temperature: Average Peak ambient Site voltage 23

24 Engineering Guide Specifications 1. Summary This section includes design, performance ratings, basic controls, and installation guidelines/requirements for the DirectGen Energy Recovery unit. 2. References Compliance with Codes and Standards NEMA 4IEEE19 (2014) ASME Section VIIIETL or UL Listed 3. Submittals Include the following: A. System dimensions including required service clearances and location of all required piping and electrical connections. B. Electrical Power Output (Gross and Net), steam temperature and pressure requirements during operation. C. Control system diagram showing points for field interface and connection to external BMS systems. Unit certified drawings shall show field and factory wiring. D. Installation and Operating Manuals, including screw expander oil capacity. E. Manufacturers performance data covering the recommended range of entering steam temperatures and ambient conditions. 4. Quality Assurance Regulatory Requirements: Compliance with the standards in section Warranty and Maintenance A. The DirectGen standard factory warranty shall be for a period of one year from date of equipment start-up or 18 months from the date of shipment, whichever occurs first. The screw expander shall have a warranty period of 3 years from start-up or 3-1/2 years from shipment. Service parts, such as filters are not included in the warranty. B. The standard factory warranty shall include parts and labor costs for the repair or replacement of parts found to be defective in material or workmanship. C. Maintenance of the DirectGen while under warranty is mandatory and shall be the responsibility of the purchaser unless the services are supplied by the manufacturers authorized service organization. Optional: - Extended 2 nd through 5 th year DirectGen parts only warranty. - 2 nd through 5 th year screw expander parts only warranty. - 2 nd through 5 th year DirectGen system (pumps, valves, controls, sensors, etc.) parts warranty. - Labor warranty available - consult factory. 5. Delivery and Handling A. The DirectGen shall be delivered to the job site with some assembly required (unless otherwise specified). B. Compliance with the manufacturer s instructions for transportation and rigging. 24

25 Engineering Guide Specifications 1. Acceptable Manufacturers A. AERCO International B. Approved Equal. Note approved equal does not automatically imply the alternate product matches this specification, functionality or delivered quality. 2. Product Description A. The oil pump and screw expander shall be configured to operate as a closed-loop circuit. The screw expander(s) and oil pump shall be designed for mechanical and electrical isolation to facilitate service and removal. B. Each DirectGen system shall include one or more screw expanders depending on unit size. The DirectGen system is designed for direct steam injection of high quality steam. 3. Design Requirements A. The DirectGen shall consist of one or more screw expanders with an external shaft (to drive a three-phase synchronous or induction power generator), steam condenser, steam separator(s), evaporative or water-cooled condensers, operating controls with equipment protection and remote monitoring capabilities. B. Unit Performance: System performance will be calculated and provided by AERCO Engineering based on customer provided conditions. 4. DirectGen Controls The controller fitted to the DirectGen shall be a microprocessor device that utilizes control software written specifically for DirectGen applications. User operation shall be accomplished using the unit mounted color touch-screen interface (HMI) or remote monitoring device. The status of the screw expander and all system parameters are visible via the human interface. Controller must include the following standard features: - Push Buttons: Auto-Start, Auto-Stop, Emergency Shutdown - Switches: Auto/Manual, Remote/Local - Lights: Power, Running, Fault, Standby - Alarm Speaker Control Panel (HMI touch screen) Provide interface for remote monitoring data through Internet TCP/IP network. A. Operator interface shall be capable of connecting directly to the DirectGen via serial communication protocol and capable of displaying system information. The unit s microprocessor is SIEMENS s7-300 PLC and it provide serial port RS 485 in MPI protocol. B. The DirectGen control panel shall contain all control functionality via a dedicated microprocessor, and data shall be served to a remote graphical user interface via an open Ethernet protocol. Proprietary protocols between any PC based or micro based processor are strictly prohibited. C. DirectGen controls shall be native BACnet capable via MSTP or IP. Addition of gateway devices or additional processors or pluggable PCBs to achieve BACnet communications to the BAS, are strictly prohibited. D. Complete configuration of native BAS communications via Modbus TCP/IP, BACnet MSTP and BACnet IP shall be made via standard DirectGen HMI. Controls that utilize external software configuration tools to configure these protocols are explicitly prohibited. 5. Sequence of Operation As the high pressure steam enters the expander, the male and female rotors turn due to rotational torque caused by the pressure differential between the high side (entering) and low side (exiting) the expander. As the steam expands as a result of the actuation between the screw rotors, the rotational energy generates kinetic energy. The rotational force of the screw expander is transferred to a high efficiency power generator via a gear coupling. A pneumatic control valve modulates to maintain a proper differential pressure across the expander. 25

26 Engineering Guide Specifications 1. Installation A. Install per manufacturer s IOM documentation, shop drawings, and submittal documents. B. Align DirectGen on a foundation or mounting rails as specified on drawings. C. Coordinate electrical installation with electrical contractor. D. Coordinate controls and BMS interface with controls contractor. E. Provide all material required for a fully operational and functional unit. 2. Start-Up Start-Up Services: Provide start-up services on-site for a minimum of 5 working days and ensure proper operation of the equipment. During the period of start-up, the factory authorized technician shall instruct the owner s representative in proper care and operation of the equipment. 26

27 Notes 27

28 Heat Hot Water Energy Recovery Solutions AERCO International, Inc. 100 Oritani Drive Blauvelt, NY USA: T: (845) Toll Free: (800) AERCO.com 2018 AERCO