30 Slides 0 3 MWZander

Dr. Manfred Renz, Manfred Engelhard

M+W Zander, Strasbourg, France September 14 2006

The New Generation Kalina Cycle

Contribution to the conference

“Electricity Generation from Enhanced Geothermal Systems”

© M+W ZanderThe New Gen Kalina Cycle at ENGINE MWZ- Eng. 14.09.06 2

M+W Zander Markts and Services

Facility Engineering

Electronics

Photovoltaics

Energy Solutions

Technical Facility Services

Pharma / Biotech / Chemical Industry

Automation

Security Systems

Facility Management

IT-Services


Scope of Services

Consulting Design Construction Operation

Consulting Services,

Evaluation,

Programming

� Site Selection Services

� Feasibility Studies� Architectural / Engineering

Programming� Economic Analysis� Financial Engineering� Process Development

and Simulation

� Design Concepts

Construction

Management

and Build

� Project Management

� Time Scheduling� Cost Control� General Contracting� Tendering� Manufacturing� Procurement

� Construction� Commissioning

� Single SourceResponsibility

� Fast Track Execution

Facility Management,

Operation,

Maintenance

� Global Facility

Management

� Real Estate Managementand Operation

� Maintenance ofTechnical Building Systems

� Energy and ConsumptionManagement

� Infrastructure Services� Commercial Services� Facility Evaluation� Security Services

Planning

and Design

� Facility Planning

� Preliminary Design� Value Engineering� Conceptual, Basic,

Detail and Final Design

� Facility Systems Integration� Permits and Environmental

Compliance� Cost Optimization


Locations Worldwide


Energy Solutions as Turnkey Supplier

1000 MW

� Siemens

� Alstom

� MHI

� Hitachi

� Bechtel

� SNC Lavalin

� …

1.000 Megawatts100 MW10 MW1 MW0,1 MW

Domestic

Energy Systems

� Viessmann

� Vaillant

� Bosch-Buderus

� Hitachi

� …

Kalina-Cycle applications

SolarthermalPower Plants

District-Heating/Cooling

Geothermal Power Plants

Biomass Power Plants

Photovoltaic Power Plants

Gas fired Power Stations

Heat Pumps

Waste Heat Recovery

Trigeneration

CHP (Combined Heat + Power) Large-Scale

Power Plants

Decentralized Energy Systems

Cogeneration and Renewable Energies


Geothermal Power Plants: Full System Contractor

Consulting ServicesProgramming� System Specification

� Environmental Permitting� Financial Engineering

Design� Design Development� Design Reviews

Kalina Cycle� Thermodynamic Calculations� Heat Exchanger interior Design

� Turbine Specification� Ammonia-Water Characteristics

Project Management

� Scheduling� Cost Control� Quality Control � Web Based Project

Collaboration

Commissioning and Ramp Up� Test and Certifications

� Putting into service� Facility Management

Training and Support

Construction� Construction Management� Material Logistics� Installation Services

� Field Engineering

Building and Facilities� Civil, Structural

and Architecture� Mechanical Systems

(air, exhaust)� Electrical Systems� Instrumentation

and Controls

Supply Systems� N2 Supply Plant

� Water Treatment System

Operation

� In Line Process Monitoring� Advanced Process Control� Web Based Visualization


Rankine Cycle Overview

Rankine Cycles

Single Fluid Mixtures

100 °C ORC

(Propane, R290)System Geothermal

New Gen. SG 2, SG 4 …

125 °C ORC

(RC318)

150 °C ORC

(i-Butane)

175 °C ORC

(n-Butan)

Kalina Cycle System

KCS 11, KCS 34 …

Water ORC Kalina Cycles

….

….


ORC – Kalina Cycle

KCS 34

Pre

heate

r

Boile

r

Pre

heate

rB

oile

r

Superh

eate

r

NH3/H2OStrong Solution

WeakSolution

Recuperator

Kalina Cycle compared to ORC

� Single organic working fluid

replaced by NH3/H2O

� Closed loop of liquid

working fluid (strong resp.

weak solution)

� Separation of steam and

liquid

Superheating possible but

normally not considered in

KCS34

� Condensation (absorption)

of vapor at low pressure

level in 2 steps

� A substantial part of

absorption energy may be

recuperated to the cycle in

HE 2


Characteristics of ORC and Kalina Cycles

Tem

pera

ture

Entropy

Organic Substances must be selectedin accordance to the heat source

temperature level (Tcr < Tin Brine)

Evaporation / Desorption Process


Cycle Caracteristics

� ORC (Single Componant Working Fluid)

� Evaporation and condensation at fixed temperatures

� Fluid must be selected in accordance to the temperature level of the heat source

� Pinch point is limiting factor for heat transfer

� Environmental impacts and restrictions by using organic substances

� Inflamable and/or toxic and/or GWP (Global Warming Potential) and/or ODP (Ozone Depletion Potential)

� Kalina Cycle (Mixture of Ammonia/Water)

� Evaporation (desorption) and condensation (absorption) over a large temperature range (fits to the nature of the heat source)

� Same working fluid may cover a wide range of the heat source temperature levels ⇒ Optimization by switching concentration

� Ammonia has toxic potential but:

� Easy to detect at save concentration levels

� A lot of experiences in handling the substance and operating ammonia cycles (mechanical and absorption chillers)

� No GWP and ODP


Kalina Cycles KSC 34 and SG 2a

KCS 34SG 2a

SG2a compared to KSC 34

� Evaporator is splitted in

preheater HE 4 and Boiler HE 5

� The working fluid is separated into 2

substreams, preheated in

HE 3, HE 4

� Evaporator HE 5 is supplied additionally by an internal

cycle, collecting working

fluid from separators

operating at intermediate

and low pressure levels

Pre

heate

r

Boile

r


Kalina SG 2a Cycle

� Increased efficiency, especially at low heat source temperatures(≤ 150°C)

� Improved adaptability to brine output temperature restrictions(scaling effects)

� Lower electricity generation loss in case of temperature restrictions

� Enhanced economic and technical viability for the utilization of low temperature geothermal sources

� Additional geothermal energy usage for heating purposes may be performed (e.g. during winter time) at less electrical power losses


Cycle Net Electrical Output Comparison

0,0

2,0

4,0

6,0

8,0

10,0

12,0

14,0

16,0

18,0

20,0

120 130 140 150 160 170 180 190

Brine Inlet Temperature (°C)

Sp

ec.

Net

Ele

ctri

cal O

utp

ut

(W

h/k

g B

rin

e)

SG-2a

SG-2d

KCS-11

KCS-34

SG-4d

ORC Double Pressure

ORC Single Pressure

Typical temperatures for geothermal

application

Source: Dr. Alexander Kalina



0,0

2,0

4,0

6,0

8,0

10,0

12,0

120 125 130 135 140 145 150

Brine Inlet Temperature (°C)

Sp

ec.

Ne

t E

lect

rica

l O

utp

ut

(Wh

/kg

Bri

ne

)

SG-2a

KCS-11

KCS-34

ORC Double Pressure

ORC Single Pressure



Kalina Cycles SG 2a and SG 2d

SG2d compared to SG2a

� Working fluid is totally evaporated and slightly

superheated in HE 6

� No intermediate pressure level

� SG 2a best performances

at temperatures ≤ 150°C

� SG 2d best performances

at temperatures ≥ 150°C

� SG2d shall be used for

high temperature

applications

SG2aSG2d



0%

20%

40%

60%

80%

100%

120%

125°C 150°C

Brine Supply Temperature

Ele

ctri

cal

Ou

tpu

t in

%

SG-2a SG-2d KCS-11

KCS-34 ORC Double Pressure ORC Single Pressure



Geothermal Power Plant - Cash Flow Comparison of different cycles

-5.000.000

-4.000.000

-3.000.000

-2.000.000

-1.000.000

0

1.000.000

2.000.000

3.000.000

4.000.000

5.000.000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Year

Op

era

tio

na

l D

isco

un

ted

Ne

t R

eve

nu

e i

n E

uro

/a

-30.000.000

-25.000.000

-20.000.000

-15.000.000

-10.000.000

-5.000.000

0

5.000.000

10.000.000

15.000.000

20.000.000

25.000.000

30.000.000

Acc

um

ula

ted

Dis

cou

nte

d N

et

Re

ven

ue i

n E

uro

SG-2a

KCS 34

ORC

SG-2a Accumulated

KCS 34 Accumulated

ORC Accumulated

Thermal water temperature 125°C

Thermal water flow rate 150 kg/s

Wet cooling tower

Financing interest 6%


Cost increase (N2, water, staff, el. power purchase) 2 % p a

ORC appr. 14,5

years

Kalina KSC 34

appr. 12,5 years

Kalina SG 2a

appr. 10,5 years


Conclusion

� Ammonia water mixture has no GWP and ODP

� New Generation Kalina Cycle SG2a is very flexible concerning project factors (heat source and heat sink adaptation)

� SG2a has the best performance at heat source temperatures ≤ 150°C

� More sellable electrical energy

� SG2a causes higher invest costs but:

⇒ Higher revenue⇒ Shorter payback period⇒ Highest possible economics of a geothermal project

30 Slides 0 3 MWZander

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