GE‘s Clean Cycle* heat-to-power generator is a compact, modular system that converts waste heat – from an array of heat sources – into power. The conversion process requires no additional fuel, produces no additional emissions, and delivers base-load power that may be used on-site or sold to the grid. GE‘s Clean Cycle J-Series is specifically designed for reciprocating engine applications utilizing the engine jacket water heat. The jacket water heat acts as a pre-heater for the Clean Cycle working fluid, and provides thermal energy – in addition to the exhaust heat from the engine – to ensure maximum output is achieved on a given engine.
GE’s Clean Cycle heat-to-power generator automatically generates the maximum power possible based on the heat transferred to the ORC and the condensing temperature. The temperature of the thermal energy delivered to the Clean Cycle heat-to-power generator can vary; the chart below assumes it is 155°C (311°F).
- Maximum gross output from generator: 140±5% kW
- Maximum grid output from power electronics**: 115±5% kW
- Working fluid evaporation temperature: 155°C, 311°F
** Includes PE and working fluid pump losses. Does not include parasitic losses from balance of plant.
- Frequency: 60, 50 Hz
- Voltage: 480, 400 V
- Power Factor: 1.0, 1.0
- Load Current (Full Gross): 168, 202 A
- Peak Starting Current: 53, 64 A
Scope of supply
Core components delivered
- The Clean Cycle skid (see p.4 for details): Standard
- Skid mounted condenser: Optional
- R245fa working fluid: Optional
- Heat source heat exchanger: Spec and/or supply
- High pressure hot water system: Spec and/or supply
- Custom condenser & system design: Spec and/or supply
- Overall system design: Optional
- Commissioning: Optional
- Gross electrical output: 50 – 140 kW
- Working fluid: R245fa (benign, non-ozone depleting)
- Power electronics: Built in inverter – matches AC grid power
- Electrical output: 50 or 60hz AC 3-phase power
- Dimensions: (384.0 x 121.9 x 217.4 cm)/(151.2x 48.0 x 85.6 in)
- Weight (not filled): 3,548kg (7,822 lbs)
- Electrical Power to grid from SEB: 3/0 3-conductor with ground
- Internet connection: Ethernet CAT-5 cable from Customer Internet
- Heat valve output to BOP: Output from Clean Cycle PLC 4-20 mA signal to control customer heat source
- Temperature input from BOP: Input from Customer 4-20 mA representing heat source supply temperature
Instrument Air; Control valve actuators: 100 PSIG (7BAR) clean/dry instrument air capable of 5 cfm
- Main Heat Source supply (HSS): (CE; DIN 80 PN40) (Non-CE; 3” – 300#)
- Main Heat source Return (HSR): (CE; DIN 80 PN40) (Non-CE; 3” – 300#)
- Jacket Water Supply (JWS): (CE; DN 80 PN40) (Non-CE; 3” – 300#)
- Jacket Water Return (JWR): (CE; DN 80 PN40) (Non-CE; 3” – 300#)
- Indirect Condenser Water Supply (CWS): (CE; DIN100 PN40) (Non-CE; 4” – 300#)
- Indirect Condenser Water Return (CWR): (CE; DIN100 PN40) (Non-CE; 4” – 300#)
- Direct Refrigerant To Condenser (RTC): (CE; DIN100 PN40) (Non CE; DIN100 PN40*)
- Direct Refrigerant From Condenser (RFC): (CE; DIN100 PN40) (Non CE; DIN100 PN40)
* Connections for direct condenser not shown/defined in illustration ** Plant piping from Clean Cycle unit to condenser to be 6 in or 15 cm
- Integrated Power Module (IPM): A high speed turbine expander integrated with a permanent magnet generator into one hermetically sealed unit. Only one moving part, no gearbox, no lubrication, no oils.
2. Single Electronics Box (SEB): Contains the core electrical components in one easily accessible enclosure
- Power Electronics Module (PEM): Converts high frequency electrical energy into 50Hz/60Hz useable power for the utility grid.Magnetic Bearing Controller (MBC): Controls the magnetic bearings to ensure that the turbine generator floats in precisely the right location as it spins. In the event of a power loss, a UPS will power the magnetic bearings until the IPM reaches zero RPM’s.Programmable Logic Controller (PLC): Provides start, run and stop controls as well as complete safety and system supervisory functions such as over-speed control, high- temperature and high-pressure limit control, fault coding, emergency shutdown, and data logging.Power distribution components & controller: Provides up to 120A of current for BOP (balance of plant) equipment. The SEB is also designed with a 5KVA transformer to convert from 480/400VAC to single phase 240/120VAC voltage that will power individual items inside of the container.Human Machine Interface (HMI): A touch panel on the SEB that handles control functions (on-site and remote) as well as data logging.
3. Receiver & working fluid: Where the working fluid, R245fa, is stored. R245fa is a benign, non-flammable, non ozone-depleting working fluid with a lower boiling point than water.
4. Heat Exchanger – Preheater: A brazed plate heat exchanger with inlet and outlet for the engine jacket water loop. The thermal energy from the engine jacket water acts as a pre-heater for the working fluid.
5. Heat exchanger – Evaporator: A brazed plate heat exchanger where the working fluid changes phase from liquid to vapor and the vapor is superheated before entering the IPM.
6. Heat exchanger – Jacket Water / Pre-Evaporater: A brazed plate heat exchanger which is dual-function. One side of the heat exchanger introduces pumped hot Engine Jacket Water heat into the working fluid, warming it to efficiently begin the evaporation process. The second side serves as a Pre-Evaporator adding more sensible heat (no phase change) into the working fluid before it enters the Main Evaporator.
7. Heat exchanger – Condenser (optional): A brazed plate heat exchanger where working fluid leaving the expander is cooled from a vapor to a liquid.
8. System pump: A multiple stage liquid pump designed for low inlet pressure and high flow rates, driven by a 15 HP motor.