An Otto Rankine Combined Cycle for High Efficiency Distributed Power Generation June ... · PDF file · 2009-06-18An Otto Rankine Combined Cycle for High Efficiency Distributed Power

An Otto Rankine Combined Cycle for High Efficiency Distributed Power Generation

June 10, 2009David Montgomery, Ph.D.

Caterpillar ARES Program Manager

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PDCOEEnergy & Sustainability

An Otto Rankine Combined Cycle for High Efficiency Distributed Power Generation - June 10, 2009

ARES Advanced Natural Gas Reciprocating Engine Systems

Funding:

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Project Description

Distributed energy systems require clean, high efficiency power generation to gain acceptance in an industry dominated by large centralized facilities.Project Team– Caterpillar Energy and Sustainability– Caterpillar Advanced Materials– Caterpillar Electronics – Caterpillar Diversified Power Products– Caterpillar Electric Power Division– Consultants– Universities

+ + = 90% U.S. Gas Engines

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Project Description (continued)Objective:By 2010, create a natural gas powered reciprocating engine system with the following attributes:

- 50% thermal efficiency- 0.1 gram/bhp-hr NOX or less - 10% reduction in life cycle costs- No loss of reliability or availability

Task Description PhaseI II III

Task 1 Component Development / Test Complete Complete PlanningTask 2 Systems Development / Test Complete Underway UnderwayTask 3 Engine Integration / Prep Complete Underway PlanningTask 4 Engine Build / Lab Test Complete Underway PlanningTask 5 Pre-Commercial Demonstration Complete 2008 2009

I 44% Efficiency0.50 g/bhp-hr NOX

II 47% Efficiency0.1 g/bhp-hr NOX

III 50% Efficiency0.1g/bhp-hr NOX

Approach:

Phased Introduction

IntegratedAftertreatment

Improved Component Systems

ARES Program Overview

Exhaust Energy Recovery

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G3520 – 44.0% Efficiency0.5 g/bhp-hr NOX

Production engine that meets ARES Phase I efficiency goals

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North America749 MWDER /

Power Security / Power Quality

Central and South America

187 MWPrime Power

Asia / Australia1005 MW

CHP / Prime Power

Europe / Africa / Mid-East

1892 MWCHP / Prime Power

3.83 GW of Caterpillar ARES Product Installed or in Process

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ARES SummaryARES program is a shining example of Public / Private partnership in technical innovation and product introduction

ARES technology provides a flexible platform for– Distributed Generation– Combined Heat & Power Applications– Renewable / Opportunity fuels utilization

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ORCC – Otto Rankine Combined Cycle

log(Volume)

log(

Pres

sure

)

Expansion

Compression

Combustion

Intake

ExhaustBlow-Down

+Otto Rankine

Enthalpy

Tem

pera

ture

Turbine

Heat to Evaporator from Exhaust

CondenserPump

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Energy (~25% of fuel LHV)in hot (>500ºC) exhaust is usually not recovered for

useful purposes

log(Volume)

log(

Pres

sure

)

Expansion

Compression

Combustion

Intake

ExhaustBlow-Down

Recovering exhaust energy will improve efficiency and thus reduce brake specific NOX and CO2 emissions.

Exhaust Energy Recovery - Motivation

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Rankine Cycle

Enthalpy

Tem

pera

ture

4

2

3

1

Turbine

Heat to Evaporator from Exhaust

CondenserPump

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Components for Parallel Recuperated Cycle:

Pump

APreheater

BEvaporator

CSuperheater

Turbine

DRecuperator

ECondenser

G3520CEngine Exhaust

Air

= Working Fluid R245fa= Engine Exhaust

To Exhaust Stack

1

2 4 5

67

8

20

303132

33

3P

3R

P_flow

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ORC System Layout

Exhaust Valve

Heat Exchangers

Condenser

Recuperator

Turbine Generator

Control Panel

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Phase-II Demonstration

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Bearing Failure

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Turbine End Bearing Non-Turbine End Bearing

Rigid Shaft

Between

Preload Path

Preload Spring (90 lb)

3 lube jets (120 deg apart at r = 1.215) per side ( 6 total)

3 lube jets (120 deg apart at r=1.215)

.47 gpm, Fluid Velocity = 20 m/s

Lube Drain Channels

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Questions?

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Turbine and Pump wheels

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Turbine Generator

Turbine, Generator, and Feed Pump on an Integral Shaft.

– 18,000 RPM Design Speed

– Total Weight: 1500 lb

Radial Turbine– 10.8” OD, 850 ft/s Tip Speed

– 365 psia @ 425 F Inlet Condition.

Generator– 4 Pole PM

– 375 KW, 600 VAC, 410 Amps, 600 Hz

– Water Cooled

Feed Pump– 320 psid

– 67 gpm

Angular contact bearings– 900,000 DN @ 18 krpm

– “Jet” lubricated with R245fa. Pump Inlet / Exit

Cooling Water Ports

Probe Feedthrough

Generator Electrical

Connections

Turbine Inlet & Exit

Ø32”

Ø15”

Documents

An Otto Rankine Combined Cycle for High Efficiency Distributed Power Generation June ... · PDF file · 2009-06-18An Otto Rankine Combined Cycle for High Efficiency Distributed Power