Andrea Burrato, GE Oil and Gas: A Development and applications of ORegen™ Waste Heat Recovery Cycle: A double closed loop system

GE Oil Gas ORegenTM Presentation for

Australian Gas Turbine Conference

Andrea Burrato

ORegenTM Product Leader

Brisbane October 30th, 2013

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ORegenTM

for Waste Heat Recovery



ORegenTM

What is ORegenTM

GE designed Organic Rankine Cycle system to recover waste heat energy from Gas Turbines exhaust (or similar waste heat sources) and produce electricity without using water or additional fuel or emissions

Developed for powergen application … mechanical drive also a possible applications

ORegenTM References

17MW system sold in Canada

17MW x 3 systems sold in China on 3 pipeline stations

17MW system sold in Brunei on a powergen station

17MW system sold in Thailand on a pipeline station



Case study ORegenTM benefits

3 GTs connected to 1 ORegen2 units running – 1 stand by

Net Output ~14 MWeProduced Power ~119 GWhr per year Saved gas ~1,160 Tj per year

... equivalento to ~38k tons/y CO2 cut

First system sold in Canada in a pipeline application

Plant overall efficiency up to 50%

14 MW of recovered power / +9 points efficiency



Why waste heat recovery?

Air

• GT simple cycle efficiency: 25-40%

• Oil & Gas GT mainly in simple cycle

• Global trends: - CO2 reduction legislation

- Increased efficiency- Increased power demand

ORegenTM

+ = Up to 17MW of power recoveryon sinlge skid

Wa

ste

he

at

* ORegen is a trademark of Nuovo Pignone Spa and is available in selected markets

• Electricity production … sell back to grid

• Help comply with emissions regulations

• Increase plant efficiency

Simple cycle GT

Exhaust Gas

Fuel

Waste heat

Gas Turbine

77% of O&G installed GT are in simple cycle



Organic Rankine Cycle is a thermodynamic cycle basedon the Rankine classic cycle using an organic working fluid

GE Research Centre selected Cyclo-Pentane as working fluid

The ORC concept

Entropy [kJ/(kg°C)]

ORC cycle T-S diagram

50

100

150

200

250

-3 -2.5 -2 -1.5 -1

Te

mp

era

ture

[°C

]

T dew T bubble T cycle @ min p T cycle @ max p

Heaters

ExpanderRecuperatorCondenserPump

Regenerator

Expansion

Condenser

Pump

Regenerator

Pre-heater

Vaporizer

Super-heater

Cyclo-Pentane C5H10

characteristics:

• Boiling point 49.3°C

• Freezing point -94 °C

• Molecular Weight 70.1

• Auto-ignition point 361°C

(Max C5 temp below auto-ignition point)

• Appearance: clear, colorless liquid

• No corrosion risk on plant equipment



ORegenTM plant schematic & scope of supply

Gas Turbine

Typical scope of supply includes:

• Diathermic oil system

• Organic C5 fluid system

• Vaporizer & heat exchangers

• Turboexpander genset

• Condenser

• C5 and oil pumps

GT exhaust

CONDENSER

HEAT EXCHANGERS

OIL HEATER

Fan

C5 Pump

Cyclopentane loop

Diathermic Oil loop

Generator

Expander

Hot Oil Pump

RECUPERATOR



17 MW Turboexpander

1 common lube oil system

4-pole synchronous generator

gearbox

Oudoor installation

with thermo-acoustic insulation

LxWxH: 13x4x5.5m

TEX designed for Zone 2

Configuration on skids:

• Ease transportation

• Installation cost reduction



Turboexpander(5-17 MW family)

2 stage variable IGVs

16-blade wheels (17-4PH)

5000 rpm shaft

10000 rpm shaft

1500/1800 rpm shaft

Double DGS +

standstill ring

4.8 expansion ratio

6.5 expansion ratio



ORegen™ Typical LayoutGT exhaust stack

Exhaust diverter (only interface with GT)

GT exhaust stack(with ORegen installed)

Control cab

DiathermalOil piping

Waste Heat

Oil heater

Turbo-Expander Generator

C5 condenser

Cyclo-pentane island



ORegenTM configurationsParallel Oil

WHRU

#1

ORCCondenser

WHRU

n

GT#1

GT#n

GT#1 WHRU

ORC#1Condenser #1

ORC#2Condenser #2

Direct

Multi cycles Parallel Gas

To be defined as typical arrangement

To be scaled up / down from a standard design

To be selected case by case. depending from the site conditions and project requirements

WHRU ORCCondenser

GT#1

WHRU ORCCondenserGT#1

- - - - - -

GT#n



GT Model GT Power

(KW)

Exhaust Flow

(Kg/sec)

Exhaust Temp

( C)

GT Efficiency

(%)

ORC Output

(MWe)

System Efficiency

(%)

GE10 (2X config) 11 250 47.5 482 31.4% 8.4 43.1%

PGT25 (*) 23 261 68.9 525 37.7% 6.9 48.9%

PGT25+ (*) 31 364 84.3 500 41.1% 7.9 51.5%

PGT25+ G4 (*) 33 973 89.0 510 41.1% 8.6 51.5%

MS5001 (*) 26 830 125.2 483 28.4% 11.3 40.4%

MS6001B (*) 43 530 145.0 544 33.3% 15.6 45.2%

MS7001E (*) 87 300 302.0 535 33.1% 31.1 44.9%

LM6000 (**) 43 397 125.6 454 41.7% 9.7 51.1%

LMS100 (**) 100 700 216.8 423 43.8% 15.7 50.8%

MS5002B (*) 26 100 121.6 491 28.8% 10.8 40.7%

MS5002C (*) 28 340 124.3 517 28.8% 12.4 41.4%

MS5002D (*) 32 580 141.4 509 29.4% 13.8 41.9%

MS5002E (*) 32 000 101.0 510 36.2% 9.8 47.2%

Reference data @ISO Conditions. 100% GT Turbine load

(*) Values at gas turbine shaft

(**) Values at generator terminals

ORegenTM output



ORegenTM CC Traditional (2 pressure levels)

Output Net 100 % 115 %

Efficiency [kWe/kWt] 23% 26%

CAPEX - Bottom Cycle 100 % 125 %

CAPEX - Water Treatment Not Required Required

OPEX - Maintenance 100 % 6000 %

OPEX - Human Attendance Not RequiredRequired

(subject to local regulation )

Installation Time 100% 120%

Plant Layout 1600 sqm 2000 sqm

Reliability (TEX vs. ST) 98% 98%

Availability (maintenance plan)Boroscope 24k hrs

Major overhaul 48k hrs

Minor overhaul 24k hrs

Major overhaul 48k hrs

ORegenTM vs Steam Combined Cycle

Note

• High level comparison between solution with same design standards• Estimation done for single WHR plant installed after a GT running at full load with 85kg/sec @ 500C exhaust gas



ORegenTM main component list

OIL SYSTEM

•Waste Heat Recovery Unit

•GT exhaust ducts modifications

(ducts, diverter & bypass stack)

•Hot Oil Expansion Vessel

•Hot Oil Circulation Pumps

•Piping system

CYCLO-PENTANE SYSTEM

•C5 Circulation Pumps

•Shell & Tube Heat Exchangers

(recuperator, pre-heater, vaporizer, superheater)

•Turboexpander Generator

•Air or Water Condenser

•Plant & TEX Control System

•Auxiliaries

•Piping System

WHRU ORegenCondenser

Skidded solution to minimize installation work



ORegen™ plant key cycle features

Designed for Unmanned operation

No need for 24/7 on-site presence of certified operators

Turndown capabilities

Best solution for GT partial load operation … @50% GT load still 80% of power recovered

Highly reliable gas Expander as main unit

No blow down

Negligible organic fluid consumption

No water requirement

No water system treatment required

Efficiency

Up to 13 points

C5 Bottom pressure

Above atmospheric pressure, High Safety (No O2

ingestion)

C5 Top pressure

Below fluid critical pressure (No supercritical operation), Best Power Recovery

Thermal Oil

Great operability Range –35° ... +330°C

Condenser sized to handle uncondensable

Compact footprint, C5 condensing above atmosphere

Specific CO2

Decrease by 40%



Condenser

BCL

Exchanger

Inlet pressure

Discharge pressure

ORegen for Mechanical Drive application

Waste heat

Flow Capability Increase

Flow Capability Increase

• Waste energy used to drive an additional compressor through an ORegen cycle

• New compressor in parallel with existing ones

Increase NG flow capability using GT waste heat



Mini ORC - 2.0 MW size

• Modular approach 2 MW size

• Minimum waste heat temp 220°C

• Different cycle parameters

• Applicable to small to medium size waste heat sources

• Optimized solution for small GT &low grade waste heat sources

Complementing ORegen for 0.5 2 MW size

Case study



Ambient data

• Average Temp 25 °C

• Elevation 0 m a.s.l. (P=1.01 bar)

• Relative Humidity 60%

Note - ORegenTM designed on average air temp of 25.0°C

Case study - Base data

#2 LM6000 Turbines installed and running

LM6000 waste heat characteristics

• Exhaust Flow 115 kg/s

• Exhaust Temp 456 °C

• Air Temp 25 °C (for air condenser design)



Case study - Solution

#2 LM6000 connected to #1 ORegen in parallel oil configurationn

#1 ORegen required



Case study - Output

Expected performance

ORegenTM Gross Power MW ~17.0

ORegenTM Net Power MW ~14.7

Net Produced Power (*) MWhr/year ~124,000

Reduced CO2 emissions (**) Tons/year ~65,000

Fuel savings (***) GJ/year ~1,150,000

(*) 8500 running hours per year

(**) generated in 1 year by a 40% efficiency gas turbine to produce the same power

(***) fuel saved by switching off 1 GT considering increasing fuel consumption on running units

#1 ORegen requiredORegenCondenser

WHRU #1 LM6000 #1

WHRU #2LM6000 #2



ORegenTM

Produce up to 17MW electric power with no additional fuel by recovering heat from GT exhaust

• Efficiency improvement 20% … CO2 footprint 20% • Carbon credits … singular enabler • Cyclo-pentane as working fluid in a closed loop … no water!

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