W E P U T E N E R G Y T O W O R K Progressive Energy ... · PDF fileProgressive Energy, Environment, and Green Supply Chain ... gerotor is a positive displacement pumping unit

W E P U T E N E R G Y T O W O R K

ENER-G-ROTORS

Progressive Energy,

Environment, and

Green Supply Chain

Summit

September 28-30, 2009


1. Energy Efficiencies in Industrial

Processes

2. Waste Heat to Electricity

3. Ener-G-Rotors 50kW Appliance

Outline

2


US Energy Flows

3


Energy Conversion is Inefficient

100 Quad BTUs Annual

Consumption

40 Quad BTUs Waste

Heat

15 Quads Low Grade

Waste Heat

• Heat Buildings

• Run Microturbines

• Thrown Away

4


0

500

1000

1500

2000

2500

3000

3500

Tri

llio

in B

tus

Energy Losses

Useful Energy

Five Sectors Account for 80% of Energy Use

Two major Energy Processes:

•Fluid Heating and Boiling

•Melting, Smelting, Metal

Heating, Calcining

* DOE - Energy Loss and Reduction

in Industrial Energy Systems, 2004

5


Onsite Energy Loss Profile Manufacturing and Mining

EERE Estimates that 20% to 50% of energy delivered to process

is loss at end of process as:

•Exit gases

•Evaporative losses

•Waste steam

•Waste hot water……

WASTE HEAT Onsite losses 32%

Energy used in Processes

35%

Possible End of Process

Losses 25%

Facilities 8%

DOE – Energy Use, Loss, and Opportunities

Analysis : US Manufacturing and Mining 2004

Boilers

Distribution

Conversion

Motors

6


Energy Footprint – e.g. Forest Products

7


DOE –Top Opportunities in Waste Heat

# Opportunity Area Industries Analyzed

Post-

Process

Energy

Savings

1

Waste heat recovery from gases and liquids in

chemicals, petroleum, and forest products, including

hot gas cleanup and dehydration of liquid waste

streamschemicals, petroleum, forest

products 851

4 Heat recovery from drying processes

chemicals, forest products,

food processing 217

10

Waste heat recovery from gases in metals and non-

metallic minerals manufacture (excluding calcining),

including hot gas cleanup

iron and steel, cement 235

16 Energy recovery from byproduct gases petroleum, iron and steel 132

18 Waste heat recovery from calcining (not flue

gases)

cement, forest products 63

19Heat recovery from metal quenching/cooling

processes iron and steel 57

1555

Table 11-2 Top 20 R&D Opportunities (Trillion Btu)[Shading indicates opportunity that will require some degree of RD&D; no shading indicates a near-

term, best practices

TOTALS

* DOE - Energy Loss and Reduction

in Industrial Energy Systems, 2004 8


●Process Streams

●Liquids

●Gases

●Condensate Streams

●Low Pressure Steam

●Combustion Gases

●Furnaces

●Kilns

●Combustion Engine Exhaust

● Turbine

● IC

●Incinerators

Industrial Opportunities for Waste Heat

9


Industrial Waste Heat

Low Temp

High Moisture

High Temp

High Moisture

Low Temp

Low Moisture

High Temp

Low Moisture

Mois

ture

Temperature

~400°F

~.05 lbw/lba

Size of stream and BTU content

10


Recovering Energy in Manufacturing

Fuels and

Electricity Steam

Direct Heat

Hot and Cold

Fluids and Gases

Power

Shaft work

P

r

o

c

e

s

s

P

r

o

c

e

s

s

P

r

o

c

e

s

s

P

r

o

c

e

s

s

Waste

Heat

Recycle High Grade Waste Heat

11

Step 1.



Fuels and

Electricity Steam

Direct Heat

Hot and Cold

Fluids and Gases

Power

Shaft work

P

r

o

c

e

s

s

P

r

o

c

e

s

s

P

r

o

c

e

s

s

P

r

o

c

e

s

s

Waste

Heat


12

Step 2. High Grade Waste Heat to Electricity


Steam Cycle

Kalina

Organic Rankine

Vendors: Recycled Energy Development,

General Electric, Ormat, Turboden,

Maxxtec

Waste Heat to Electricity Technologies

Only Economical at Large sizes

(>1MW)

And High temperatures

(>400°F)

13


Until Now Only Large Systems Economical

14


●Energy is Renewable – no primary fuel used in

production

●Efficiency Improved

●Environmental Benefits - no emissions

●Economical – free fuel

Waste Heat Recovery - Impacts

15



Fuels and

Electricity Steam

Direct Heat

Hot and Cold

Fluids and Gases

Power

Shaft work

P

r

o

c

e

s

s

P

r

o

c

e

s

s

P

r

o

c

e

s

s

P

r

o

c

e

s

s

Waste

Heat


16

Step 3.

High Grade Waste Heat to Electricity


Low Grade Heat is Thrown Away


The Face of Low Grade Waste Heat

$ $ $ $ $ $ $ $ $ $

1 MW

1,000s of similar sites across US and World

18


Customer Drivers

●Save money

●Reduce energy costs

●Drive efficiency

●Minimize risk

●Volatility in energy prices can’t be passed to

customers

●Energy prices expected to rise with carbon tax

●Green marketing

● Increase energy from renewable sources ($)

●Public relations

$ $ $ $

19



Fuels and

Electricity Steam

Direct Heat

Hot and Cold

Fluids and Gases

Power

Shaft work

P

r

o

c

e

s

s

P

r

o

c

e

s

s

P

r

o

c

e

s

s

P

r

o

c

e

s

s

Waste

Heat


20

Step 3.

High Grade Waste Heat to Electricity

Low Grade Waste Heat to Electricity


Ener-G-Rotors Heat to

Electricity Systems

21


Organic Rankine Cycle

Pump

HEAT INPUT

HEAT REJECTED

GENERATOR

Working Fluid

Expander

22



Pump

HEAT INPUT

HEAT REJECTED

GENERATOR

Working Fluid

23


Until Now only Large Systems Available

24


Current Technologies Are Limited

●Turbine expander ● Inefficient at small sizes

● Inefficient at low temps

●Solutions must be…. ●Economical : <3 year payback

●Modular

●Non-disruptive to customer

●Low maintenance

250

150 400

1

Turbines

Temperature (°F) G

en

era

tor

siz

e (

kW

)

25


50kW Heat to Electricity Appliance

●Economical

●$90,000 purchase price (1.8 $/W)

●$42,000 of electricity/year at $.10/kWh

●281 tons/year CO2 reduction

●Modular

●3 ft wide x 10 ft long x 6 ft tall

●Light enough to fit on roof

●Non-disruptive

●4 hoses ; 1 wire

●“Hot” installation

●Low Maintenance

●20 year life

●Maintenance needs similar to refrigerator

Current 5kW System;

50kW will look the same

26


The Enabling Technology :

A Modified “G” Rotor

●Gerotor

● gerotor is a positive displacement pumping unit.

● The name gerotor is derived from "Generated Rotor".

● A gerotor unit consists of an inner and outer rotor. The inner

rotor has N teeth, and the outer rotor has N+1 teeth.

● The inner rotor is located off-center and both rotors rotate.

● Uses

● Oil pumps

● Fuel pumps

● High speed gas compressors

● Engines

● Hydraulic motors

● Power steering units

27

http://en.wikipedia.org/wiki/Positive_displacement_pump

http://en.wikipedia.org/wiki/Rotor_(turbine)


The Innovation

●Hold the rotors on preloaded bearings to control very tight

tolerances - US Patent # 6,174,151

● Substantial reduction in friction

● Significant decrease in gear set wear

● Holds tolerances to reduce leakage

● Vapor Expansion driven

●Use it as an Expander

The innovation allows for a highly efficient, low maintenance

“heat engine” for use at low temperatures

28


How It Works

Output Port

(shaded)

Inner Rotor (yellow)

Outer Rotor (dark blue)

Input Port

(shaded)

Expanding vapor drives open chamber, creating rotary motion

29


●Simple, elegant design ●11 parts, 2 moving parts

●No exotic materials

●No exotic manufacturing processes

●Significant Increase in Expander Efficiency ●Low thermal losses

●Low friction losses

●Low leakage

●Durable ●Few moving parts

●No sliding contacts

● Internal lubrication

The Trochoidal Gear Engine™ Expander

30


Ener-G-Rotors 5kW Beta

31



Pump

HEAT INPUT

HEAT REJECTED

GENERATOR

Working Fluid

32


< Two Year Payback

●Cost/benefit play

●Assumptions

●50kW system

●$90K purchase price

●Not including installation, which could be $2K -$20K

●100% utilization

●Payback period

●2.1 years at $0.10/kWh

●3 years at prices higher than $0.065/kWh

33


Ener-G-Rotors 5kW Beta

34


Generation 1 Original Design

0.6 -0.7 kW

Generation 2 5kW Prototype

Model for Patent

Generation 3 5kW System

First "appliance"

Includes controls

Increased efficiency

Run over extended time

Generation 4 50 kW System

2000 2002 2004 2006 2008 2010

First three sold Harbec Plastics

Con Ed

NYSERDA

Generation 5 100kW System?

250kW System?

Back to 1kW?

35


Applications

400°F 150°F 200°F 250°F 300°F 350°F

Water

Hot Air

Steam

Hot Water /Steam 190°F to 240°F Phase I

Hot Air 240°F to 330°F Phase II

Hot Water 150°F to 190°F Phase III

Hot Air 190°F to 240°F Phase IV

36


Potential Markets

●Industry

●Petroleum/Coal

●Chemical

●Pulp and Paper

Products

●Primary Metals

●Food

●Non-metallic Mineral

●Buildings

●High-rises

●Schools (K-12)

●Supermarkets

●Other

●Wastewater treatment

37


●Energy conversions are in-efficient

●Waste heat accounts for significant percentage of energy used

●Use of waste heat adds considerable efficiency ●Lowers production costs

●Conserves energy resources

● Increases productivity

●Lowers emissions

●Easy to extract value from high temperature heat

●Enabling technologies in low temperature waste heat are here

Summary

38


Ener-G-Rotors, Inc.

Thank You

39

Documents

W E P U T E N E R G Y T O W O R K Progressive Energy ... · PDF fileProgressive Energy, Environment, and Green Supply Chain ... gerotor is a positive displacement pumping unit