A low grade marine Waste Heat Recovery Unit is a system designed to capture and convert low-grade waste heat from ship engines into usable electrical power. It uses an organic working fluid with a lower boiling point than water, allowing it to operate efficiently at lower temperatures compared to traditional steam cycles.
As they typically follow the Rankine cycle using organic fluids, they are often referred to as Organic Rankine Cycle (ORC) units.
The key components of a waste heat recovery unit based upon the ORC design are as follows:
A. Evaporator:
- Heat exchanger that transfers thermal energy from the waste heat source to the working fluid
B. Turbine:
- Expands the high-pressure vapor, converting thermal energy to mechanical energy
C. Generator:
- Coupled to the turbine, converts mechanical energy into electrical power
D. Condenser:
- Cools and condenses the low-pressure vapor back to liquid state
E. Working Fluid Pump:
- Pressurizes the liquid working fluid and circulates it through the system
F. Recuperator (optional):
- Internal heat exchanger that preheats the liquid working fluid using residual heat from the turbine exhaust
G. Control System:
- Monitors and regulates system parameters for optimal performance and safety
We can provide the following engineering services associated with the design and installation of a waste heat recovery unit.
- Feasibility Study and Concept Design:
- Evaluation of space availability and weight considerations
- Preliminary process flow diagrams
- Conceptual layout designs
- Initial cost estimates and project timeline
- Detailed Engineering Design:
- Process engineering and equipment sizing
- Piping and Instrumentation Diagrams (P&IDs)
- 3D modeling of the equipment layout
- Electrical system design and integration
- Equipment Specification and Procurement Support:
- Development of technical specifications for major equipment
- Vendor evaluation and selection assistance
- Review of vendor documentation and drawings
- Structural Modifications Design:
- Reinforcement designs for existing structures if required
- Finite Element Analysis (FEA) for critical structural components
- Integration Engineering:
- Interface design with existing ship systems (e.g., power, water)
- Modification of existing piping systems
- Safety and Risk Engineering:
- Failure Mode and Effects Analysis (FMEA)
- Regulatory Compliance and Classification:
- Liaison with classification societies
- Preparation of documentation for class approval
- Development of procedures to meet regulatory requirements
- Installation Planning:
- Development of detailed installation procedures
- Creation of work packages for shipyard or offshore installation
- Lift plans for major equipment
- Installation sequence optimization
- Commissioning and Start-up Support:
- Development of commissioning procedures
- Supervision of installation and commissioning activities
- Performance of system tests and trials
- Troubleshooting and optimization support
- Documentation and Training:
- Preparation of operating and maintenance manuals
- Development of crew training programs
- Environmental Impact Assessment:
- Analysis of the recovery unit’s environmental benefits
- Support for environmental permit applications
- Project Management:
- Overall project scheduling and coordination
- Cost control and progress reporting
- Quality assurance and control
- Lifecycle Support:
- Development of maintenance and inspection schedules
- Optimization studies for long-term operation
- Technical support for system upgrades or modifications
- Feasibility Study and Concept Design: