Waste Heat Recovery at Compressor Stations

The path towards novel and high-impact technologies and their implementation
Gas Electric Partnership Houston, TX Feb 10-11 2010 Presented by Southwest Research Institute Matthew Blieske Marybeth Nored Melissa Wilcox Buddy Broerman

Presentation overview

waste heat recovery (WHR) basics ! current technologies ! previous research the path forward - whr for onsite use ! small to medium scale ! large scale ! energy storage ! augmentation of other systems engineering economic analyses of selected cases ! organic rankine cycle ! co2 refrigeration Future work

WHR Basics
Denition: Using the remaining heat/thermal energy to create useful energy

Useful Energy
Electricity Power/Torque Preheat & Refrigeration Low Grade Steam Hot Water

Common Heat Losses

Gas Turbine Exhaust* 72% IC Engine* Exhaust! ! Jacket Cooling! Lube Cooling! IC Engine Total! 35% 18% 20% 73%

*McKee, R., Energy Audit Results from a Typical Natural Gas Compressor Station, Proceedings of GMC, 2001.

Current WHR Options Gas Turbine

Organic Rankine Cycle
! ORC Common Applications: Geothermal, solar panels, biomass, and cement plants ! Compressor Station Average Size: 5.5 MW ! Power available for local use or for sale ! INGAA White Paper ORC Economics

Installed Cost ~ $2000 2500/kW

" "

Station Capacity > 15,000 hp Operation at least: 5,250 hrs / 12 months

Current WHR Options Gas Turbine

Turbine Inlet Air Cooling
! Current trend: Inlet Fogging (poor performance in humid and cool regions) ! Exhaust heat used in refrigeration cycle (applicable in most installations)

Preheating Fuel
! Many applications require this to prevent liquid dropout ! Additional heater used for preheating (could use exhaust heat instead)

Regeneration
! Preheat air going into combustor ! Applicable to low pressure ratio gas turbines (less than 10:1)

Current WHR Options IC Engine

Turbocharger ! Pre-compress inlet air to engine (boost in power) ! New developments Preheating Fuel Inlet Air cooling ! Classically for GT but can provide benets for IC engines

Current WHR Options Other

Turboexpanders
! Generate power at pressure reduction points ! Applications LNG and hydrocarbon processing applications (steady ows and pressure ratio) ! Require either pre or post gas heating to avoid liquid dropout " Waste heat from another source can supply this ! Average Installed cost ~ $1450/kW

commercially available products

Calnetix TG-100 ! uses 250+ oF waste liquid or gas as an input, generates electricity ! offshore packaging available Ormat Energy Converter (OEC) ! uses R245fa refrigerant in a rankine cycle ! sized for 2-15 MW ! electrical output

commercially available products

Turbothermal ! uses a novel expander to generate electricity as part of a rankine cycle ! targeted for 250-750 kW voith ! steamdrive/steamtrac ! outputs shaft power to ic engine ! available for transportation industry, looking for application in the energy eld

examples and case studies

Organic Rankine Cycle

Utilize a standard Organic Rankine Cycle with a working uid of pentane to compare pipeline transmission driver options. Purpose was to understand variations in recovered power without regard to cost of installation. Through a relative thermodynamic comparison, can identify opportunities for smaller scale, lower cost waste heat recovery: utilizing ORC or other energy conversions such as central thermal storage, thermal batteries, pre-heating solar / fuel cells. Engine drives for reciprocating compressors have other waste heat losses that could be captured these were not considered in this portion of the analysis.

Approach to Analysis
Thermodynamic ORG analysis utilized to study various exhaust ow rates and energy content, for typical GT and engine drives (1-15 MW). Analysis considered primary component efciencies, all other factors remained the same (ambient temperature, pentane cooler temperature, etc.). Compared results to INGAA survey of recoverable power vs. rated power of installation. Economic considerations were not considered, as purpose of analysis was to determine technology gaps and opportunities for recoverable power.

Cases considered in analysis

Modeling utilized known driver power, exhaust ow characteristics. Combined heat energy input with basic thermodynamic analysis of pentane-based Rankine cycle.

INGAA Cases and SwRI Examples: Recovered Power Estimates

INGAA Cases + SwRI Thermo Examples: Comparison of Recoverable Power

Note: Interesting trend in % return in power (recoverable power / rated power) for small GT drive applications.

Additional economic considerations enter into lower power installations .

Divergence in Potential Low Side and High Side Recovery with Higher Exhaust Power

Recovered Power Estimation for ORC

Recoverable Power Varies from 10-17% (somewhat independently of amount of waste heat power). Recoverable power depends on exhaust ow rate, temperature, selected ORC pressure, other optimized cycle parameters.

Inlet Cooling
Several cycles suitable for inlet cooling ! transcritical refrigeration cycles
" " " " "
effective for extracting low grade heat high power density emerging technology, modest commercial exposure in transportation and residential markets effective on medium to large scale requires mechanical/electrical work input for refrigerant compressor

! absorption chillers ! vapor compression cycles

Absorption chillers for inlet cooling

can deliver cooling load on exhaust heat

input alone

eliminates the need to pump a gas (high

energy process) by absorbing vapor refrigerant into hydrate solution

! org cycle requires electrical input to provide cooling

only moving part is the refrigerant pump

rotor

! two most common uids are lithium-bromide-water and ammonia-water

 two main types of construction

! single effect

Absorption chillers for inlet cooling

! double effect

" single generator " COP of 0.6-0.8 " commercially

available

" two generators " cop of 1.0-1.2 " higher capital cost " some longevity and
maintenance issues

Absorption chillers for inlet cooling

double effect chiller

Absorption chillers for inlet cooling

Prime Mover (mechanical drive) medium gas turbine ISO rated shaft power (hp) 15,000 exhaust ow (lb/hr) 335,560 exhaust Cooling temperature capacity (tons) o ( F) 905 4343

large gas turbine medium SI gas engine large SI gas engine

29,500

536,400

990

8056

1004

9756

834

109 / 92*

5124

72,000

784

719 / 427*

* cooling power from exhaust / engine coolant

Absorption chillers for inlet cooling

Prime Mover (mechanical drive) % exhaust ow energy recovered Primer mover efciency Combined cycle efciency

medium gas turbine large gas turbine medium SI gas engine large SI gas engine

75.3 78.9 65.7 65.0

34.0 36.1 34.5 45.6

80.4 82.6 67.1 93.7

Absorption chillers for inlet cooling

Performance with chilling system
Prime Mover (mechanical drive) inlet primer mover temperature efciency o ( F) shaft power (hp) efciency improvement power increase

medium gas turbine large gas turbine medium SI gas engine large SI gas engine

40 40 40 40

34.9 38.2 34.5 45.6

16,752 2.6% 31,451 5.8% 1077 5498 <0.5% <0.5%

11.7% 6.6% 7.3% 7.3%

NOTE that % improvement is relative to 77oF 14.65 PSI standard atmosphere

Absorption chillers for inlet cooling

note that more cooling is produced than what can be used by an individual prime mover
! ! Chiller can also cool pipeline gas on hot days to improve efciency and capacity of compressors single chiller can cool multiple units

inlet temperature reduction limited by the cooling water temperature of 40oF for lithium bromide could combine medium IC engine running chiller with large gas turbine
! would be able to chill both engines, and pipeline gas

efciency and capacity improvements more dramatic for operating conditions above 77oF

Past Experience

Waste heat sources at compressor stations well understood SwRI GMC paper (mckee, 2001), Swri GEP presentation (2008-2009) Hoerbiger gmc paper (mathews et. al., 2008) INGAA report (Hedman, 2008)

scale of economy a factor in success power export requires a utility who will play ball, and access to the grid on-site uses have received less attention

Past Experience

the economics have been favorable for alliance pipeline, who continue to retrot stations with Ormat WHR systems largely due to a favorable power purchase agreement with saskpower

Shift in Technology Development

focus on electrical export leaves small to remote stations dont have access to the

medium stations out due to economy of scale grid, whr for electrical export not possible sources/demands i.e. gas turbine starting or stations not operating 24/7 addressed (could be viable for small scales)

few economical solutions for intermittent potential to export thermal energy not

GMRC/PRCI 2010 research plan

Sources of Waste Energy Gas Turbine: Exhaust heat Connection Technologies Turboexpander CO2 Refrigeration Microturbine Thermoelectrics Thermal Storage ORC Cycle Energy Harvesters New Technology Electricity: Starting power Auxiliary power systems Energy storage Valve actuation Parasitic demand End Uses at Station Heat/Pressure: Export gas temp control Heat solar panels (optimize) Human environmental control Component environmental control Energy storage Pre-heating uids Valve actuation

IC Engine: Exhaust heat Cooling uid heat Lube oil heat

Other: Pressure reducing valves Vent gas Gas cooler heat Flare heat Vibration

technology development roadmap

Gaps in Knowledge

does it make sense for storage (mechanical,

thermal, electrical) to be an integral part of whr strategies?

! what are the scenarios that make storage attractive? ! centralized vs. distributed are there source/end-use pairings that do not have a suitable technology to bridge them? ! is anyone trying to ll these gaps? what optimization is required for current technologies? ! tailor energy outputs (thermal vs. electrical) to on-site demands

Conclusion
waste heat recovery solutions that do not export electrical power do not receive much attention currently, yet have the potential to address an under served market (small-medium stations) focused research and development in on-site use and/or export of other energy forms is needed

Questions?