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Friday, November 21, 2008

Electricity from Waste Heat

Ener-G-Rotors' system harvests energy at lower temperatures.

By Jennifer Kho

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More than hot air: Ener-G-Rotors, which claims that its technology can cost effectively generate electricity from low-temperature waste heat, plans to install its first five-kilowatt sample system in December. The system (bottom), which uses a rotor instead of a turbine to run a generator (top), is approximately four feet high.
Credit: Ener-G-Rotors

Factories, data centers, power plants--even your clothes dryer--throw off waste heat that could be a useful source of energy. But most existing heat-harvesting technologies are efficient only at temperatures above 150 °C, and much waste heat just isn't that hot. Now Ener-G-Rotors, based in Schenectady, NY, is developing technology that can use heat between 65 and 150 °C.

The company replaces the turbine in a typical electrical generator with a device called a gerotor, which it claims to have made "near frictionless." "If this works, it's so huge," says Bob Bechtold, president of Harbec Plastics, one of Ener-G-Rotors' potential customers. "I've been dreaming about the concept of using [low-temperature waste heat] ever since I first knew what it was about . . . It's all about using what we have more completely."

Ener-G-Rotors' technology is based on the Rankine cycle, in which heated fluid flowing through a tube heats a pressurized fluid in a second tube via a heat exchanger. The second tube is a closed loop; the so-called working fluid flowing through it (a refrigerant with a low boiling point, in the case of Ener-G-Rotors) vaporizes and travels into a larger space called an expander. There, as the name would imply, it expands, exerting a mechanical force that can be converted into electricity.

Instead of turning a turbine, the expanding vapor in Ener-G-Rotors' system turns the gerotor, which is really two concentric rotors. The inner rotor attaches to an axle, and the outer rotor is a kind of collar around it. The rotors have mismatched gear teeth, and when vapor passing between them forces them apart, the gears mesh, turning the rotor.

The company claims that the rotor design is far simpler than that of a turbine, making it potentially easier and cheaper to manufacture, as well as more durable. And the company says that it has invented a proprietary way of mounting the rotor on rolling bearings that makes its movement nearly frictionless.

Reducing the friction means that the rotor turns more easily, so the gas doesn't need to exert as much force to generate electricity. That's why the system can work at lower temperatures, which impart less energy to the gas.

The company expects to convert 10 to 15 percent of low-temperature waste heat into electricity, delivering a payback in two years or less in most cases, says CEO Michael Newell. Ener-G-Rotors plans to both sell systems to customers outright and operate its own systems and sell power.

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  • Off Shore Application
    mkogrady on 11/21/2008 at 2:17 PM
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    I recall reading there was a test of a similar system in the 1960's off Florida where the DOE deployed a closed loop system that used the thermal difference between the surface water temps and lower water temps. As the fluid cycled through, it hit a hit a gaseous state - drove a turbine and then recondensed to liquid again. The internal fluid (ammonium something or other) was too corrosive and the system eventually wore out prematurely.

    If this newer approach pans out, it could be a huge tool to be used in offshore applications where currents are not as prevelent, but the thermal differences are signiificant. The Sea of Cortez off CA and Mexico could become a hug power plant or smaller inland lakes in developing countries could be candidates.

    When does Ener-G-Rotors go public?
    Rate this comment: 12345
  • Ideal solution for Geothermal electricity generation
    kjblack on 11/27/2008 at 12:41 AM
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    This unit would be ideal for the generation of geothermal electricity where the temperature is between 65C to 150C
    There are areas in Victoria, Australia, where the temperature is marginal to run a geothermal plant at the above temperatures.
    Nodoubt there are other areas in the world in the same situation.
    I have read in the past where thermal temperature difference in the ocean has been utilised in Hawaii to generate electricity.
    Rate this comment: 12345
  • Blacktop Parking Lot Powerplant
    jmaximus9 on 11/29/2008 at 1:35 AM
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    What about running a heat adsorbing PVC pipe under a large blacktop [asphalt] parking lot [Home Depot or Walmart]. The blacktop adsorbs heat like a battery, then the pipe reclaims this heat to boil a refrigerant, like ammonia to power the generator.

    Ever try to walk barefoot on asphalt in the summer time, at the beach? The hotter it gets the better this works.

    This would also have substantial counter heat island effect. The term "heat island" describes built up areas that are hotter than nearby rural areas. The annual mean air temperature of a city with 1 million people or more can be 1.8–5.4°F (1–3°C) warmer than its surroundings. In the evening, the difference can be as high as 22°F (12°C).

    Using this waste heat you prevent it from warming our urban/suburban world. Depending on the technology used, cool pavements can improve stormwater management and water quality, increase surface durability, enhance nighttime illumination, and reduce noise.

    Heat islands can affect communities by increasing summertime peak energy demand, air conditioning costs, air pollution and greenhouse gas emissions, heat-related illness and mortality, and water quality.

    Cool pavements can indirectly help reduce energy consumption, air pollution, and greenhouse gas emissions.
    Rate this comment: 12345
    • Re: Blacktop Parking Lot Powerplant
      hachi on 11/29/2008 at 3:41 AM
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      Hate to see it pierced accidentally and ammonia let off into the enviroment
      Rate this comment: 12345
      • Re: Blacktop Parking Lot Powerplant
        Siphon on 12/05/2008 at 11:47 AM
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        You don't have to use ammonia. In fact there are thermodynamically better and nontoxic refrigerants out there. Some have been developed that are nonflammable, nontoxic and have zero ozone depletion and global warming potential. There's dozens of organic fluids that can be used.
        Rate this comment: 12345
    • Re: Blacktop Parking Lot Powerplant
      Siphon on 12/05/2008 at 11:49 AM
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      Sounds promising. Not for the urban heat island effect though; efficiency isn't high enough to help substantially.

      Painting roofs white or in pastel colors helps a lot though. As do greenroofs. And they're beautiful to look at as well...
      Rate this comment: 12345
  • Ener-G-Rotors
    a.sabeer on 12/17/2008 at 3:31 AM
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    1
    Can anyone tell me the formulae for estimation of power from ener-g-rotors.........
    Rate this comment: 12345
  • generating electricity from waste heat from a gas oven
    kkeeven63 on 01/01/2009 at 11:30 AM
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    1
    I own a couple of pizza franchises and I am looking for a thermol generator that will convert waste heat from a brick oven that operates at 650 degrees for 12 - 14 hours per day and continues to generate heat for an additional 12 hours of at least 350 degrees.  Is there any product available to convert this waste heat.
    Rate this comment: 12345
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