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7/27/2019 ORC and Kalina Analysis and Experience
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ORC and KalinaAnalysis and experience
Pll Valdimarsson
professor of mechanical
engineering
Sabbatical December 2003
Lecture III
2
Energy and energy use
Energy is utilized in two forms, as heat
and as work
Work moves, but heat changes
temperature (moves the molecules
faster)
These are two totally different products
for a power station
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Convertability
Work can always be changed into heat
(by friction since ste stone age)
Conversion of heat into work is difficult
and is limited by the laws of
thermodynamics. A part of the heat
used has always to be rejected to thesurroundings
4
Heat and work again
Work is the high quality, high priced
product
Heat is second class quality, a low
priced byproduct
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A power plant
Source
Heat
Fuel
Rejected heat
Losses
Electricity
Sellable heat
Power
plant
6
Single flash - condensing
Production well Injection well
Separator
Turbine
Cooling tower
Pump
Condenser
Pump
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T-s diagram
8
ORC with regenerator
Production well
Injection well
Turbine
Condenser
Pump
Regenerator
Boiler
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T-s diagram
-2,0 -1,5 -1,0 -0,5 0,0 0,5 1,0-50
0
50
100
150
200
250
s [kJ/kg-K]
T[C]
2300 kPa
1000 kPa
350 kPa
90 kPa0,2 0,4 0,6 0,8
0,00
45
0,026
0,063
0,15
0,37
0,89
m3/kg
Isopentane
10
ORC with paralell single flash
Production well Injection well
Separator
Turbine Cooling tower
Condenser
Pump
Condenser
Cooling towerTurbine
Boiler
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ORC with serial single flash
Production well Injection well
Separator Turbine
Condenser
Cooling towerTurbine
Boiler
Throttling valve
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Rogner, Bad Blumau
The 250 kW air-cooled geothermal CHP plantgenerates electrical power as well as districtheating using a low temperature geothermalresource.
One standard containerized ORMAT CHPmodule, generating 250 kW electricity and2,500 kW heat.
The power plant is in commercial operationsince July 2001.
16
Mokai, New Zealand
The 60 MW Geothermal Power Plant iscomprised of: one 50 MW module operating on geothermal
steam
two 5 MW units operating on geothermal brine
The power plant uses air-cooled condensersand achieves 100% geothermal fluid
reinjection to produce electrical power withvirtually no environmental impact.
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Kalina
Production well
Injection well
Separator
Turbine
Condenser
Boiler
Throttling valve
Cooling tower
Regenerator
Pump
Brine hx
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Geothermal experience
Rough surroundings
Aggressive chemistry
Simple and reliable solutions
Geothermal energy - a mayor economic
factor
20
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Conversion of heat to electricity
The Carnot efficiency applies for infinite
heat sources
The maximum efficiency is lower than
the Carnot efficiency for a source
stream with finite heat capacity
Kalina reduces entropy generation inthe heat exchange process
22
Carnot efficiency
Hot reservoir
Cold reservoir
Work output
Heat in
Heat out
1
01T
TCarnot
=
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Maximum efficiency
for a liquid source
=
21
2
1
0
)(
ln
1*TT
T
T
THEh
x
1T
2T
0T 0T
24
What is a Kalina process?
A modified Rankine cycle, or rather:
a reversed absorption cycle
Ammonia - water working fluid
Patented by Exergy Inc and A. Kalina
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The characteristics
Heat is added in a combined boiling and
separation process
at a variable temperature
Heat is rejected in a combined
condensation and absorption process
as well at a variable temperature
260 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
60
80
100
120
140
160
180
200
220
240
Temperature[C]
Ammonia mass fraction [-]
Mixture boiling at 30 bar
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Heat addition - boiler
Source
Kalina
ORC
28
The working fluid
Ammonia has a molar mass of 17, so
steam turbines can be used
The mixture properties are more
complex, usually three independent
properties are needed for the
calculation of the fourth Therefore the cycle is more flexible, and
can be closely optimized to the source
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The benefit
The working fluid is almost at the
temperature of the source fluid when
leaving the boiler
The variable heat rejection temperature
makes regeneration possible
30
Kalina vs. ORC
Kalina is better when the heat source
stream has a finite heat capacity
ORC and Kalina are similar when the
source is condensing steam
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Boiling curves for Hsavk
0 200 400 600 800 1000 120020
30
40
50
60
70
80
90
100
110
120
Temperature[C]
Enthalpy [kJ/kg]
Water
KalinaORC
32
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Kalina again
Production well
Injection well
Separator
Turbine
Condenser
Boiler
Throttling valve
Cooling tower
Regenerator
Pump
Brine hx
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0 200 400 600 800 1000 1200 1400 1600
0
50
100
150
200
Enthalpy [kJ/kg]
Temperature[C]
T - h diagram
6.5
6.5
6.5
6.5
31
31
31
31
6.5
6.5
6.5
6.5
31
31
31
31
6.5
6.5
6.5
6.5
31
31
31
31
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Comparison
Power[kW]
1. law 2. law Maxliquideff.
Volumeto
turbine[m3/s]
Kalina 2000 0,13 0,45 0,56 0,57
ORC 1589 0,10 0,36 0,45 2,06
Flash cycle 1589 0,10 0,36 0,45 22,4
Themoelectricity 720 0,05 0,16 0,20 0
40
Comparison of Kalina and ORC
Heat (10MW) is available down to 80C
Cooling water (120kg/s) is available at
20C
Heat exchangers have a pinch of 3C
Condensers have a pinch of 10C
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90 95 100 105 110 115 120 125 130 135 1400
0.05
0.1
0.15
0.2
0.25
Temperature [C]
Efficiency[-]
Carnot
LiquidKalina
ORC
42
Hsavk geothermalpower plant
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General design parameters
44
Summary
Commissioned in the summer 2000
Running at ~1500 kW net 2000 - 2001
Running at ~1700 kW net since
November 2001
Final acceptance certificate issued
Total investment cost 3,7 MEUR
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Process
diagram
G121 C
80 C
90 kg/s
1950 kW
5 C
24 C
118 C
31 bara
5,5 bara
12 C
67 C
16,3 kg/s
173 kg/s
0,81 NH3
130 kW
11,2 kg/s
46
The power plant
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Design
Standard industrial components
Turbine-generator from KKK, Germany
Electrical components CE marked
Heat exchangers from USA
Most of the tanks made in Iceland
Installed by a local contractor
48
Equipment
Evaporator, shell and tube, 1600 m2
Separator
Turbine
Recuperators
Condenser, plate, 2 x 750 m2
Hotwell
Circulation pump
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Auxillary equipment
Ammonia storage tank
Demineralized water tank
Blow down tank
50
Thermal equilibrium
Power output
Power input
14.000 kWCooling water
1.700 kWElectricity, net
15.700 kWBrine
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Start-up problems
Separator
Evaporator
Axial sealing of the turbine, ammonia leakage
Condensers
Miscellaneous
Main pump
Safety valves
Magnetite
52
Separator
Difficult to measure the performance of
the separator
Mist eliminator module wrongly installed
New separator installed November 2001
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Evaporator
Ammonia leaking into the hot water
All tubes rolled again in November
2001, no leakages since
54
Axial sealing
One axial sealing on the low pressure
side
N2 used in the sealing
The sealing has been replaced once
Leakage caused by carry-over from
separator
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Condensers
Plate heat exchangers
Important to mix liquid and vapor
Spraying nozzles modified
Increase power output by improving
performance of the condensers
56
Miscellaneous
Safety valves, leakage
Circulation pump, seals and
guides/bushings for shaft
Improvment of spraying system in
recuperator 2
Magnetite (Fe3O4)
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Turbine corrosion
Ferritic material in the turbine corrodes
Austenitec material is unharmed
Corrosion is from the turbine control
valve until abt 1 metre after the turbine
Influence of rotor magnetic field?
Elimination of ferritic material in the steamside of the turbine
58
Operating experience
Maximizing the output by optimizing the
strength of the NH3 H2O solution
Prevent air entering the system
Improvement of flushing and filters
The system is stable in operation
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Lessons learned
The technology is proven
Standard equipment has been adjusted
The plant is running according to specs
Individual equipment still may be
improved to increase output
Engineering details will improve future
plants
60
What do we have?
New thermodynamic cycle with better
efficiency in particular when the heat source
cooled down while heat is extracted
Theoretical and technical descriptions of the
processes involved.
Mathematical models that have been tested
up against Husavik Plant
Known media and known machinery
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The knowledge
Real experience and know how from theHusavik plant
Mathematical models and ,,steamtables, worked out in cooperation withUniversity of Iceland.
Over 30 years of experience in electrical
generation from low and mid heatsources (Geothermal)
62
Kalina references
Canoga Park, USA, demonstration plant3 6 MW, 1991-1997
Fukuoka, Japan, incineration plant, 4,5MW, 1999
Sumitomo, Japan, waste heat recovery
from a steel plant, 3,1 MW Husavik, Iceland, geothermal plant, 2,0
MW, 2000
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Krafla 1970, 60 MWel
Svartsengi 1980, 37 MWel, 60 MWdh
Nesjavellir 1990, 90 MWel, 250 MWdh
64
Were does it fit?
Temperature above 150C and good
size stands on its own.
Cogeneration of electricity and water for
district heating.
Good cold end helps
Environmental issues and subsidizing
changes these values
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65
Budgetary unit price
Budgetary price for 500 kW unit
720.000 USD
Equals 1440 USD/kW
Turbine/generator most costly unit (30-
35%)
Presuming cooling water available
66
Opportunities
Where there may be hot water or other
fluid/gas available at temperatures
between 120 and 300C
Geothermal
Waste heat
Industrial processes
Gas and diesel engine exhaust
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Kalina plant benefits
Energy cost efficient
Environmental issues
Green energy
Reduced emissions
Standard off the shelf equipment
68
General marketconditions
General market price 4 eurocents/kWh
General pay-back time 4 years required
General investment 1000 USD/kW
So how can 1440 USD/kW becompetitive?
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German law
Green electrical power generation bonus
2002-2004 1,74 eurocents/kWh
2005-2006 1,69 eurocents/kWh
2007-2008 1,64 eurocents/kWh
2009-2010 1,59 eurocents/kWh
Provided plant in operation before end of 2005
70
Competitive investment ?
Given 1,65 eurocents/kWh bonus
4 year pay-back period
Additional investment acceptable for
green energy USD 528.000/MW
Total acceptable investment cost thus
USD 1.528.000/MW or 764.000 USD for
our 500 kW unit.
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Green energy?
Is waste heat recovery=green energy?
Waste heat recovery reduces emissions
CO2 quotas pricing as high as 20-25
USD/tonCO2
Average emission 800 gCO2/kWh in
fossil fuel plants
Equals values of 1,8-2,2 eurocents/kWh
72
Summary
Given green energy bonuses or CO2
evaluation the investment in a Kalina waste
heat recovery electrical generating plant is
feasible
The investment is competitive to other
investments for industrial improvements
Pay-back time of 4 years in a green energy
technology is short
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Introduction
Finite source heat capacity lowers this upperbound due to the reduction of the sourcetemperature as heat is removed from thesource
This results in high cost for such lowtemperature power plants, as they have tohandle large heat flows
The Kalina cycle is a novel approach toincrease this efficiency
74
The Models
It is assumed that a fluid is available attemperatures ranging from 100 to 150C
A heat customer is assumed for the primaryoutlet water at the temperature of 80C
Primary flow of 50 kg/s is assumed
Cooling water source is assumed at 15C,
and cooling water outlet is fixed at 30C It is assumed that a cooling water pump has
to overcome a pressure loss of 1 bar on thecooling water side in the condenser
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Solution
The software Engineering Equation Solver (EES) is
used to run the models
The cost model keeps the logarithmic mean
temperature difference for each heat exchanger at
the same value as found in the cycle data for the
tenders for the Husavik power plant
Estimated cost figures for individual components
were then added together in order to obtain the finalcost value
76
Process assumptions
The OCR model is based on a system
without regeneration
Isopenthane is assumed as a working
fluid
A Kalina cycle for generation of
saturated vapour for the turbine is used
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ORC flow sheet
Production well
Injection well
Turbine
Condenser
Pump
Boiler
78
Kalina flow sheet
Production well
Injection well
Separator
Turbine
Condenser
Boiler
Throttling valve
Cooling tower
Regenerator
Pump
Brine hx
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Kalina assumptions
This cycle will be limited by the dew point of the mixture,that is when the boiling of the mixture is complete, andno liquid remains at the boiler outlet
The bubble temperature of the mixture has to be lower orequal to the primary fluid outlet temperature to ensuresafe operation
The feasible region will be in the area between the 70and 80C bubble contours
The feasible area regarding the dew temperature is
limited to a value some 2-4C lower than the maximumtemperature of the primary fluid
Bubble temperature
10
20
30
40
0.6
0.8
1
20
40
60
80
100
Pressure [bar]
Bubble temperature
Ammonia ratio [-]
Bubbletemperature[C]
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Dew temperature
10
20
30
40
0.6
0.8
150
100
150
200
Pressure [bar]
Dew temperature
Ammonia ratio [-]
Dewtemperature[C]
Bubble contours
10 15 20 25 30 35 400.65
0.7
0.75
0.8
0.85
0.9
0.95
1
Pressure [bar]
Ammoniaratio[-]
Bubble temperature contours
30
40
40
50
50
60
60
70
70
70
80
80
80
90
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Dew contours
10 15 20 25 30 35 400.65
0.7
0.75
0.8
0.85
0.9
0.95
1
Pressure [bar]
Ammoniaratio[-]
Dew temperature contours
80 90
100
100
110
110
110
120
120120
120
130
130
130130
140
140
140
140
150
150
150
160
160
160
170
170 18
0
19
84
More Kalina
Both high pressure level and ammonia content aredesign variables in the Kalina cycle
This gives flexibility in the design of the cycle, andrequires as well a certain design strategy
The plant can be designed for maximum power
or with strong demands on the investment cost
The cost is 100 for the lowest cost, and the power100 for the highest power
An x denotes an infeasible solution, the cycle will notbe able to run at these ammonia content pressurecombinations
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Cost contours
15 20 25 30 35 400.65
0.7
0.75
0.8
0.85
0.9
0.95
1
Pressure [bar]
Ammoniaratio[-]
Cost contours, 100C source
101
101
101
102102
102
102
103
103
103
10
3103
104
104
104
104
105
105
105
105
106
106
106
106
107
107
107
107
107
108
108
108
108
109
109
109
109
110
110
110
110
110
Power contours
20 25 30 35 400.65
0.7
0.75
0.8
0.85
0.9
0.95
1
Pressure [bar]
Ammoniaratio[-]
Power contours, 100C source
9090
9090
9090
9090
90
90
90
9090
90
9191
91
9191
9191
919191
91
9191
92
92
92
9292
9292
9292
9292
92
93
93
9393
9393
9393
9393
93
94
94
94
94
94
9494
94
9494
94
9595
95
9595
9595
95
9595
96
96
96
9696
96
9696
9797
97
97
97
97
9797
9898
98
98
98
99
9999
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Cost surface
10
20
30
40
0.6
0.8
10
200
400
600
Pressure [bar]
Cost function
Ammonia ratio [-]
Cost
Power surface
10
20
30
40
0.6
0.8
1
0
50
100
Pressure [bar]
Power function
Ammonia ratio [-]
Power
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89
Discussion
The best power and best cost points are
different
The lowest cost is at 32 bar, 92% ammonia, but
highest power is at 34 bar and 88% ammonia
This leads to the definition of two different Kalina
cycles, the best power and the best cost cycles,
with different pressure and ammonia content
15 20 25 30 35 400.65
0.7
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Pressure [bar]
Ammoniaratio[-]
Cost contours, 120C source
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22 24 26 28 30 32 34 36 38 400.65
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Pressure [bar]
Ammoniaratio[-]
Power contours, 120C source
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18 20 22 24 26 28 30 32 34 360.65
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Pressure [bar]
Ammoniaratio[-]
Cost contours, 150C source
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Power contours, 150C source
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Comparison
Two ORC companies made a tender inthe Husavik bid
Manufacturer A offered a high power,high cost power plant, wheremanufacturer B took a moreconservative approach
Following is a comparison with both thelow cost and high power Kalina powerplants
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Cost comparison
100 110 120 130 140 1501000
1200
1400
1600
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2000
2200
2400
Source inlet temperature [C]
Netcost[$/kW]
Kalina vs ORC cost comparison
ORC B
ORC A
Kalina HP
Kalina LC
Power comparison
100 110 120 130 140 1500
500
1000
1500
2000
Source inlet temperature [C]
Netpower[kW]
Kalina vs ORC power comparison
Kalina HP
Kalina LC
ORC A
ORC B
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Results
The maximum power generated for a
given source is greater for the Kalina
cycle
Kalina cycle is well positioned against
an ORC cycle for applications with high
utilization time, a base load application
98
Results II
A heat consumer is beneficial for the ORC
cycle as it results in less temperature change
of the primary fluid during the boiling process
The Kalina cycle has the boiling or
vaporization of the fluid happening over a
temperature range up to 100C, which is
beneficial when the primary fluid returntemperature has to be minimized
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The debate
The theoretical efficiency and cost/productionratio are better for Kalina as shown above
Other arguments like difficulties withmachinery and lesser operational security oruptime are only temporary discussion items,as always for a new technology
These arguments were exactly the samebetween conventional flash cycle and ORCwhen the latter popped up 30 years ago withbetter efficiency but little track record
100
Conclusion
The Kalina cycle is thermodynamically
superior or equal to the ORC cycle
There is no black magic behind the
Kalina cycle
The startup problems that have either
been solved, or are solvable