ORION-100
Mini-turbine Technology
The ORION Power International
ORION-100 CHP
Today, ORION offers the ORION-100 CHP for combined
heat, power and air-conditioning (CHP). Fuelled by natural gas (diesel or
kerosene – optional), it produces electricity, heat and air-conditioning using
an absorption chiller.
The ORION-100 is based on a
Mini-turbine Engine
These very small high speed gas turbine
engines are simple radial designs, closer in concept to low cost turbochargers
than the more complex axial designs of large industrial engines, which are often
derived from aero engines. Conservative operating temperatures eliminate the
need to use high cost sophisticated materials, which together with their
simplicity is conducive to low cost when produced in volume.
In comparison with reciprocating engines,
they attract lower maintenance costs, produce lower vibration, lower emissions
and are more compact, making them the ideal engine choice for co-generation (CHP)
systems.
Turbo Alternators
A conventional small gas turbine generator
set consists of a high speed turbine (e.g. 50k rpm) coupled to a low speed
electrical machine (e.g. 3k rpm) through a reduction gearbox. However, the power
output of an electrical machine is proportional to speed. Consequently, if the
electrical machine (alternator) is run at turbine speed it is so small that it
can be integrated into the engine on the same shaft as the turbo machinery
forming a compact high speed generator or Turbo Alternator. The gearbox is no
longer required and the alternator also acts as a starter motor to further
reduce the size of the generator set.
The ORION definition of a
Mini-Turbo-Generator (MTG) is where a high speed generator is used and runs
at turbine speed on a single or multi-shaft system. The primary power range for
this Turbo-Generator technology is 100 kW to 500 kW. However, for certain
applications it is expected to be used down to a baseline of 85 kW and up to 1
MW.
ORION’s
systems cover the range of 100kW to 500kW, with systems up to 2 MW planned for
delivery in 2004.
Recuperators
Durable heat exchangers of high
effectivity and low cost are needed to increase the
efficiency of gas turbines to the levels needed to compete with reciprocating
engine based power generation systems. Their function is to preheat the air used
in the combustion process and thereby reduce the amount of fuel used to reach
operating temperature.
The ORION recuperator
is a primary surface type, manufactured from stainless steel for long life. With
an effectivity of about 90%, the fuel consumption of
the mini-turbine engine is approximately halved, doubling the MTG efficiency
from 15% to about 30%.
Power Conditioners
The electrical output frequency of a Turbo
Alternator is typically 1000 to 3000 Hz and must be converted to 50 or 60 Hz. A
microprocessor controlled Power Conditioner carries out the frequency
conversion, and other power conditioning and utility connection functions, to
provide electrical power of appropriate quality and features. The Power
Conditioner controls output frequency independent of turbine speed and
facilitates the variation of speed with load to save fuel.
The ORION Power Conditioner is designed in
house and provides the functionality to allow the MTG to operate in parallel
with the utility supply (Grid connected) in Export or Load Following mode, or as
a stand alone system (Island Mode). Integrated engine control and management
capability together with remote control and monitoring is a further feature of
this module.
ORION Cogeneration (CHP) Systems
The ORION Cogeneration System consists of
an MTG carefully integrated with a waste heat recovery boiler to provide a
compact, high efficiency, low emission and virtually vibration free system
producing heat and electrical power.
Cogeneration (CHP) systems burning natural
gas, diesel or kerosene, incorporate two key areas of technology;
ORION has developed and integrated high
efficiency stainless steel waste heat recovery units, which enable hot water at
90 degrees C. to be produced from the exhaust gas stream.
It is possible to produce chilled water
from an absorption chiller, which again would recover the waste heat from the
gas turbine exhaust stream. Turbogen will interface
with existing low temperature hot water fired absorbtion
chillers and ORION are jointly developing more effective direct fired
absorbtion chiller packages.
Gas Boost Compressors
Natural gas is the fuel of choice for
stationary power plants. Pipeline gas is usually supplied to small users at low
pressure, typically less than 1 psi. An MTG requires
gas at 60 to 80 psi, therefore an efficient low cost
durable Gas Boost Compressor is needed.
ORION are developing suitable technology
in association with experienced air and refrigeration compressor manufacturing
companies and now have units from two suppliers available for commercial use
subject to completion of certification.
Wide range of applications
Until the present time many consumers have
found that the smallest economically viable CHP system would typically utilize a
gas reciprocating engine with an electrical output of around 150kWe. These
systems are too big for many customers and so ORION has developed this new type
of mini-turbine powered cogeneration unit to bring the benefits of CHP to a
large section of smaller consumers. Typical use of the ORION-100 Cogeneration
system could be in offices, shops, hotels, hospitals, residential homes, small
industries, schools, supermarkets, leisure centers and swimming pools, apartment
blocks and small scale district heating schemes.
The two primary market segments
identified and initially targeted by ORION are:
The product is attractive in a variety
of additional market segments.
-
Stationary Combined Heat and Power
systems (Cogeneration & Trigeneration)
-
General purpose portable Generator Sets
-
Uninterruptible Power Supply systems
(Battery and Generator systems)
-
Ground Power units for the aviation
industry
-
Distributed Power Generation Systems
(Electrical and Cogeneration)
-
Renewable Energy/Environmental projects
(land fill/biogas applications)
-
Auxiliary Power Units for equipment on
board vehicles
-
Vehicle based generator sets for the
drive trains of Hybrid Electrical Vehicles
Product Features and Benefits
Compared to a reciprocating engine a
mini-turbine offers the following advantages:
-
compact and light weight
-
multi-fuel and low emissions, especially
with natural gas
-
virtually vibration free, long design
life and low operating cost
-
very simple design and low parts count
offers low production cost in volume
-
better part load efficiency through
variable speed operation.
Compared to a central power station a MTG
offers the following benefits:
-
Low, or no, electrical transmission and
distribution (T&D) losses
-
Avoidance or deferral of increased T&D
costs
-
Use
of the engine heat output for high efficiency Cogeneration &
Trigeneration
-
Variation of the heat/power ratio
locally. This enables the system to be heat or power demand lead and extends
the annual operating hours
-
Greater consumer control
-
Remote
control and monitoring of local power quality and power features
-
Well suited to providing power to rural
and developing regions
-
Allows incremental increase in capacity
at small levels of incremental cost
-
Avoidance of substantial approval
process problems for new plant and associated T&D
-
Significantly reduces environmental
impacts
-
Minimal civil and installation costs.
Features of the Orion Power International
ORION-100 Cogeneration Product
The ORION systems offer the following
standard and optional features:
-
Recuperated or simple cycle Mini-turbine
Generator
-
Pre-engineered compact Package
-
Gas fuel capability
-
Alternate fuels: Diesel and Kerosene
(Optional)
-
Low Emissions
-
High operational flexibility allowing
both 'Heat or Power demand following'
-
Low acoustic noise level
-
Low temperature hot water output (90
degrees C.)
-
Capability to produce high pressure hot
water
-
Capability for steam production
-
Power output with utility network
interface for grid connection (Option)
-
Power output for stand alone operation
(Option)
-
Peak shaving and load following
(Options)
-
Remote control and monitoring (Options)
-
Data logging (Options)
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