The OriGen. Clean, Renewable Power From Waste Heat. AERCO.com

Transcription

1 The OriGen Clean, Renewable Power From Waste Heat AERCO.com

2 Turning Waste Heat into Usable Power What is Energy Recovery? Energy recovery is the method of using the waste heat of one process as the input that powers the next process. Using this waste heat (i.e., exhaust, waste hot water), 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. *estimated by the Energy Information Agency 2

3 The OriGen: Energy Recovery for Your Enterprise The OriGen Although the concept of energy recovery isn t new, previous technology was only able to capture high temperature waste heat from enormous industrial complexes that s less than half of all waste heat discarded into the environment. Now, AERCO s OriGen is able to capture and turn low- to medium-temperature waste heat into clean, usable electrical power. Because of this capability, the OriGen can be used across an extremely broad range of applications everything from landfills and oil refineries to food and beverage manufacturing plants and even office buildings. Instead of burning fossil fuels, the OriGen generates power using waste heat in a continuous, closed loop, so it s fossil fuel-free and emissionfree. Saving energy by not burning additional fossil fuels translates directly into saving money ROI is typically within three to five 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 OriGen, 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. 3

4 How it Works - Organic Rankine Cycle (ORC) Technology The OriGen uses ORC (Organic Rankine Cycle) technology and operates with proven, conventional HVAC components in a continuous cycle, closed system so NO emissions are produced. How it works: 1. Waste heat (as hot water) enters the evaporator and heats the refrigerant* to boiling 2. The high-pressure refrigerant vapor leaves the evaporator and enters the screw expander spinning rotors quickly driving a generator to produce power 3. To continue the cycle, the refrigerant vapor leaves the screw expander at a lower pressure and enters the condenser where it is cooled by the cooling source and condensed to a liquid 4. The cooled liquid is sent to the pump, increasing its pressure, then enters the evaporator where the refrigerant is boiled (starting the cycle again) Refrigerant Cold Water Hot Water 1 Waste Heat Source Advantages of a Screw Expander vs. Turbine Most energy recovery products that incorporate ORC technology use a turbine expander. The OriGen 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. 4 Pump Evaporator Condenser 3 2 Screw Expander Cooling Source Generator (power) The OriGen s Twin-Screw Expander vs. Other Screw Expanders The OriGen 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. It s what makes the OriGen so OriGinal. *The OriGen uses R245fa refrigerant, the most environmentfriendly industrial refrigerant 4

5 Features and Benefits With ORC technology and the innovative twin-screw expander the OriGen is able to create clean power for an extremely broad range of applications. Its power output ranges from 55kw to 5MW and can be combined to generate higher output plants. With payback within three to five years, you can t afford not to incorporate one into your enterprise. Clean, Renewable Power with No Carbon Footprint Clean power generation from low- and mediumquality waste heat sources (170 F to 600 F) from a variety of applications including: - Heat Recovery - Biomass - Geothermal/Solar Power output ranging from 55kW to 5MW No fossil-fuels consumed No toxic emissions produced (operates in a closed loop system) Modular and scalable to accommodate larger plants Significant Savings Three to five year ROI Very low operating and maintenance costs (system is self-powered and completely automated no operator required) Substantial state and federal rebates available Considerable utility cost savings and decreased rates due to the OriGen reducing peak demand 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 System efficiencies of 20%+ (with dual loop) 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) Combined Heat Power (CHP) systems available Turnkey package the entire unit is pre-packaged and comes on one skid module or multiple modules depending on system size (except condenser) Available with multiple condenser configurations that meet various site requirements We customize to site conditions, and take care of installation and start-up to ensure performance is optimized 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 OriGen 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 OriGen 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 OriGen helps develop the distributed power network. By allowing users to consume supplemental, non-grid power locally, the OriGen 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 OriGen 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 OriGen not only reduces carbon footprint, it produces a negative one! 6

7 Heat Recovery Applications Industry provides an abundance of opportunities to recover heat and convert it into renewable power. The OriGen works well with low and medium exhaust as well as inconstant heat sources, making it ideal for larger plants or smaller factories and office buildings. The clean power generated by the OriGen can be used to power your enterprise, sold back to the local power grid and/or used for CHP systems where applicable. Examples of applications include: Landfills/treatment/waste disposal (e.g., sewage plants) Food and Beverage industry Dry Condenser Petroleum industry (e.g., oil and gas refineries) Ceramic/glass industry Chemical industry Metallurgy processing and steel mills Industry Electric Power Condenser OriGen Wet Condenser/ Cooling Tower River/Lake/Pond Geothermal/solar industry Power generation Heat Exchanger CHP Systems District Heating Decentralized power plants Mobile power plants Waste Heat Thermal Storage/ Hot Water Air Drying HVAC 7

8 Landfill Applications There are thousands of landfills nationwide. For landfills which already incorporate a landfill-gas generator, the OriGen will increase efficiency generating an additional 10-18% of power output. For new landfill sites, we ll work with you to determine the most efficient operational set-up for your site. Landfill-gas Generator Dry Condenser Condenser Landfill Electric Power River/Lake/Pond OriGen Heat Exchanger Geothermal 8 Wet Condenser/ Cooling Tower

9 Biomass Applications Biomass is available practically everywhere and is typically very economical. Examples include using fuels like timber and sawdust in sawmills, sugarcane in factories, and even straw, green cuttings, manure or other organic waste material. The OriGen can produce both electricity and hot water (CHP) for use as space or industrial process heating. Dry Condenser Condenser Wet Condenser/ Cooling Tower Electric Power River/Lake/Pond Biomass OriGen CHP Systems Heat Exchanger District Heating Waste Heat Thermal Storage/ Hot Water Air Drying HVAC 9

10 Geothermal/Solar Applications The OriGen is able to generate electrical power from geothermal resources including natural hot springs, geothermal wells, and solar hot water systems. Dry Condenser Condenser Geothermal Electric Power River/Lake/Pond OriGen Heat Exchanger Solar Hot Water 10 Wet Condenser/ Cooling Tower

11 OriGen Models Technical Data OriGen Model Gross Power Output (kw) Water Cooled System Net Power Output (kw) Evaporate Tower System Net Power Output (kw) Entering/ Leaving Design Point (ºF) Hot Water Temperature Entering/ Leaving Design Point (ºC) Hot Water Mass Flow GPM Condensing Temperature Design Point (ºF) Design Point (ºC) Voltage/ Ph/Hz Generator Type* ORG / / /3/60 Induction ORG / / /3/60 Induction ORG / / /3/60 Induction ORG / / /3/60 Induction ORG / / /3/60 Induction ORG / / /3/60 Induction ORG / / /3/60 Induction *Synchronous generators available as an option Installation Examples Geothermal/Solar New Mexico, USA (4-8 MW) Alaska, USA (270 kw) New York, USA (130 kw) Waste Disposal Wenzhou, China (200 kw) Chemical Plant Quzhou, China (3000 kw) Steel Mills Tianjin, China (3000 kw) Henan Yaxin, China (3000 kw) Yunli, China (3000 kw) New Mexico - pulls 315 F (157 C) heated water via 3,600 foot geothermal well and provides power to the local utility grid Alaska - provides power to a local resort using geothermal heat from a hot spring 11

12 Heat Hot Water Energy Recovery Solutions AERCO International, Inc. 100 Oritani Drive Blauvelt, NY USA: T: (845) Toll Free: (800) AERCO.com 2017 AERCO