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Organic Integration and Optimization for High Efficiency CHP Genset Systems

Combined and (CHP) systems Current (ORC) systems operate at relatively low provide both electricity and heat for their and are used as a bottoming cycle recovery solution (top figure). The ORC host facilities. CHP systems have mostly system being developed can operate at higher temperatures and can thus be the saturated the large industrial facility primary recipient of the heat from a reciprocating (bottom figure). market, where economies of scale and the presence of needed technical staff make Photo credit ElectraTherm. the deployment of large systems greater than 20 megawatt (MW) electrical capacity a reciprocating engine to achieve total manufacturing sector analysis conducted cost effective and practical. There remains, CHP system efficiencies of 85% or more for the U.S. Department of , however, substantial room for growth of at both its rated electrical capacity and at widespread deployment of flexible CHP smaller CHP systems suited for small and 50% capacity. To achieve this goal, the systems that are able to provide grid mid-size manufacturing facilities. system will be capable of operating in services could result in annual financial higher temperatures and than benefits of approximately $1.4 billion In addition to manufacturing facility typical ORC systems. in the state of California alone. These energy benefits, the needs of the modern savings consist of lower industrial site electric grid are other potential drivers Benefits for Our Industry and energy costs, reduced grid operating costs, for further deployment of CHP systems. Our Nation and capacity value of the new electric As intermittent renewable generation generators. resources constitute a growing and If successfully developed, the new ORC increasingly significant portion of system with a higher and Applications in Our Nation’s , the need for rating will allow a CHP system Industry to maintain the to generate more power and generate stability of the grid grows. Many small and hotter at the discharge, leading to A CHP system consisting of a high- mid-size manufacturing facilities would be a total CHP system efficiency of 85% or efficiency reciprocating engine and the ideal hosts for flexible CHP systems that more. Such a high-efficiency CHP system developed ORC system will be suitable for can provide needed grid services. would result in fuel and cost savings for many small and mid-size manufacturing industrial, commercial, and institutional facilities with both electrical and thermal In order for CHP systems to be facilities. loads. Because of the higher temperature seamlessly integrated with the grid and of the rejected heat from the ORC system, provide more advanced grid services, Because of the projected high CHP system it is suitable for most space heating further technical development is needed. efficiency at part load conditions, the new applications. This increases the number For such CHP systems to be cost- ORC technology would also contribute to of potential host sites when compared to effective and able to respond to changing the development of flexible CHP systems typical ORC systems. grid conditions, they must be able to that could be used to provide needed grid maintain high system efficiency at partial services, such as additional generating Flexible CHP systems that can load conditions and have the ability to capacity during times of and provide grid services are expected to ramp up or down quickly. voltage regulation. Having such flexible be financially attractive investments CHP systems could provide significant in markets with high penetration of This project seeks to enable a novel financial benefits to the host facility, intermittent renewable resources, flexible CHP system concept by but also to the grid system operator such as California, Texas, and several developing an Organic Rankine Cycle and all ratepayers. According to a 2018 Midwestern states. (ORC) system that can be integrated with

ADVANCED MANUFACTURING OFFICE ADVANCED MANUFACTURING OFFICE

Project Description approximately 185°F. The project team Technology Transition will explore different variants of a high This project seeks to develop an pressure expander and feed , heat If the new ORC system is successfully ORC system that operates in higher exchanger alternatives, and new working demonstrated, ElectraTherm will reach temperature and pressure ranges, which fluids to achieve this goal. out to reciprocating engine manufacturers will allow the waste heat leaving the to educate them about the technology. system to be utilized for a wider range of The new high pressure expander In this marketing effort, ElectraTherm applications, including space heating and solution will build on screw compressor will rely heavily on its parent company cooling. To achieve this goal, the project technologies developed by BITZER, the BITZER’s well-known global name team will explore different variants of a parent company of ElectraTherm and and market presence. The highly high pressure expander and feed pump, world’s largest independent manufacturer efficient and flexible CHP systems alternatives, and new of compressors. The project being enabled by incorporating the working fluids. The ORC system will team will utilize two tools developed ORC system will be suitable for many be designed to match a reciprocating by ElectraTherm to model and evaluate commercial, institutional, and small and engine with a 1 MW capacity or more. different types of hardware and ORC mid-size manufacturing facilities with The project goal is to be able develop a system configurations, reducing the time both electrical and thermal loads. If the CHP system with electricity generation and effort needed for system development system can provide an attractive return efficiency of 45% or greater and total and testing. on investment, there is much room for system efficiency of 85% or greater at growth for such CHP systems in the 1-20 rated electrical capacity, and electricity Two ORC system prototypes will be MW capacity range. generation efficiency of 30% or greater constructed. The first prototype will be and total system efficiency of 85% able to run at the targeted temperature Project Partners or greater at 50% of rated electrical and pressure conditions, and data from capacity. the initial prototype will be used to ElectraTherm validate the ability of the system models Flowery Branch, GA Barriers to predict cycle performance in the new Principal Investigator: Tom Brokaw operating range. Once the system model Email: [email protected] • Need for a highly optimized heat is validated, it can be used to find optimal recovery system to achieve 85% total system components for the second Jenbacher CHP system efficiency at 50% of rated prototype. The second prototype will be electrical capacity Susteon Inc. evaluated in a test cell to confirm that the Durham, NC • Upgrading all ORC system components reciprocating engine and ORC system to be able to operate in higher combination will achieve project goals For additional information, for efficiency. temperatures and pressures please contact • Increasing ORC condensing Milestones Bob Gemmer temperature high enough to be Technology Manager compatible with existing hydronic This three-year project began in late U.S. Department of Energy heating systems 2018. Advanced Manufacturing Office • Design and construction of an initial • Identification of new working Phone: (202) 586-5885 prototype ORC system capable of Email: [email protected]  fluids that achieve desired system operating at higher temperatures and performance and have very low global pressures (2019) warming potential • Update and validation of Pathways model based on prototype test data (2020) ORC systems are a proven technology to utilize low-temperature waste heat to • Design and construction of a new ORC generate electricity. In a typical system system prototype capable of meeting configuration with a reciprocating engine, project goals (2020) ORC is used as a bottoming cycle and • Operation and performance validation the highest temperature leaving the of the new ORC system (2021) condenser is in the range of 120°F. In order for the waste heat to be used for • Completion of techno-economic and facility heating and cooling applications, technology to market analyses (2021) the waste heat leaving the ORC should be For more information, visit: energy.gov/eere/amo

DOE/EE-1912 • April 2019