Process flow and gathering

system
Session VI

Eln Hallgrmsdttir and Lilja Tryggvadttir

Mannvit Strasbourg, Nov.8, 2012
 Presentation overview
Presentations reviewing different work cycles
Main concept of the gathering system
Calculated example showing methods used
within geothermal steam gathering system
design
Geothermal in Iceland
 Process flow
A review of thermodynamic cycles used in
geothermal energy production with emphasis
on electricity generation
Flash steam cycles with single flash and
double flash as well as different binary cycles
as ORC and Kalina Cycle are introduced and
compared
Back Pressure Steam Power Plant
2 phase flow Vapor Turbine Generator
Phigh
Steam
separator G
Liquid
Plow

Production wells Reinjection wells

Back pressure unit - layout
Separator Asphalted area for installation and maintenance purposes

Machine Hall

Electrical cabinets &

Control room
 Calculated examples
Different turbine outlet pressure 700

600

500

Turbine Power [kJ/kg]

400

300

200

100

0
1,2 1 0,8 0,6 0,4 0,2 0
Turbine outlet pressure [bara]
Steam Power Plant with Condenser
Silencer

Steam Turbine Generator

Geothermal
fluid
G
Steam Mist
separator eliminator Cooling tower

Production wells

Gas Extraction System

Water Condenser

Condensate

Condensate
Reinjection wells
Steam Power Plant Double Pressure
Two phase Steam
flow separator HP steam Turbine - generator

LP steam
G

Two
phase LP Steam
flow separator Condenser Tcw

Cooling system

Production wells Reinjection wells

Svartsengi theOctopus
Steam Power Plant Double Flash
Steam supply system Primary steam Turbine - generator

G
Steam Secondary steam
LP Turbine - generator
separator

G
LP Steam
separator Condenser Tcw

Cooling system

Tcw

Cooling system

Production wells Reinjection wells

Hellisheii low pressure unit
Steam Power Plant w. District Heating
Steam supply system Primary steam Turbine - generator

G
Steam
separator
District To district
heating heating
system

Condenser

Tcw

Cooling system

Production wells Reinjection wells Freshwater wells

District heating plant
Well head silencers
Process Flow Diagram
Steam separators Mist separators
Two phase flow Steam Generators
Pressure
regulation Turbines

Cooling
towers

Production wells Condensers

Cold water pump

Geothermal water
Condensers
Geothermal water
emergency exhaust

De-aerators
Hot water tank

De-aerators

Re-injection wells
25. 02. 2008 Heat exchangers
 Binary Cycles
Phigh
Turbine Generator

Tsource
G
Evaporator

Tdischarge Plow

Condenser Tcw

Cooling system

Circulation pump
Binary Cycles with Recuperation
Phigh
Turbine Generator

Tsource
G
Evaporator

Tdischarge Plow

Recuperator

Condenser Tcw

Cooling system

Circulation pump
Binary Plant Berlin El Salvador
LaGeo
 Binary Cycles Kalina
Separator

Turbine Generator

Tsource High temp

G
recuperator
Evaporator

Tdischarge

Low temp
recuperator

Condenser
Tcw

Cooling system

Circulation pump
Hsavik Kalina plant
 14 0
ORC 12 0
Kalina

11 0

12 0

10 0

Temperature
10 0
Temperature

90

80

80

60

70

40

60

20

55 0 50 0 45 0 40 0 35 0 30 0 25 0 20 0

50

0 0, 2 0, 4 0, 6 0, 8 1

Heat transfer Heat Transfer

 Binary Cycles Kalex
Tsource

Tdischarge

Cooling system
Work Cycle Comparison
Specific Power
Work Cycle Cost Comparison
12

10

8
/W

6 Kalina
Kalex
4 ORC

0
80 85 90 95 100 105 110 115 120 125 130
Inlet Temperature [C]
 Steam supply system Turbine - generator

G Primary binary
turbine - generator

Secondary binary Cooling system

turbine - generator

Evaporator
G

Cooling system

Production wells Reinjection wells

 Demonstration of model
Turboden ORC model:
http://www.turboden.eu/en/rankine/rankine-
calculator.php
 Gathering System
This session will present an overview of the
design process of a geothermal gathering
system with emphasis on particularities of the
geothermal fluid.
 Steam Supply - Preliminary P&ID
Steam separators Mist separators
Two phase flow Steam Generators

Turbines

Pressure
Production wells Cooling
relief
towers

emergency exhaust Condensers

Geothermal
water

Re-injection wells
 Nesjavellir Power Plant
Cooling towers Steam
Power pipelines
Plant

Production Two phase

Well flow
Steam vent
station
Separation
station
 Gathering system- Design

Design standards 1400

quartz solubility (F&P82)

Standards i.e. 1200 amorphous silica solubility (F77)

Pressure directive 1000

SiO2 (mg/kg)
97/23/EC 800 330 C

300 C

Pressure selection 600

270 C

400 240 C

Chemical constraints 200

Power generation 0
1.00 10.00 100.00

Productivity curves Pressure (bar-a)

 Chemical constraints
Scaling
Corrosivity
Radioactivity

Mitigation:
Pressure control / closed loop system
cleaning of the steam
Inhibitors
 500
Assumptions:
Power generation
Total turbine efficiency: 0,8
450

400 h = 2200 kJ/kg

Turbine power [kJ/kg]

350
h = 2000 kJ/kg

300
h = 1800 kJ/kg
250

h = 1600 kJ/kg
200

150

100

50

0
0 2 4 6 8 10 12 14 16 18 20
Separator pressure [bara]
Typical productivity curves
Well Pump Low Enthalpy

Type
Submersible pump
Line shaft pump
Selection and operation
Depth
Temperature
Scaling
Bubble point
 Gathering System Design load
Constant load
Weight
Pressure
Variable load (depending on location)
Wind load
Snow load
Earthquake
Frictional load
Thermal expansion
Friction
 Gathering System - Pipelines

Pipe laying
Under ground
Above ground
Material selection
Pipe size
Pressure/temperature
Steam Supply System Pipelines
1000

900
Pipe diameter [mm]

800

700

7 bar-a
600
20 bar-a
500

400

300
0 20 40 60 80 100 120 140 160

Flow [kg/s]
 Gathering system route selection
Public safety
Environmental impact
Restriction on land
Cost efficiency
Steam pipelines
 Steam Supply - Layout
Central separation station
Satellite separation stations
Individual separators

Central Satellite Individual

Power plant layout
Steam Supply - Separators

Cyclone separators
Gravity separators

Efficiency
Steam separator and moisture separator
should together achieve 99,99 % bw.
liquid removal or better
 Calculated example
The presenter will go through a calculated
example to show methods used for basic
engineering within steam gathering system
design. The example taken will be connected
to the special conditions encountered in
geothermal energy.
 Example
Example for 1200 kJ/kg well enthalpy
40-50C condensing temperature
Back pressure

Objective
Maximize the power production
 Assumptions
We know the reservoir enthalpy
We know the condenser temperature
Separation pressure does not influence the well
flow
Example, condensing unit
 Example, condensing unit
The maximum power will be 12,4 MW
Entalpy = 1200 kJ/kg
Condensing pressure 0,075 bara / temperature
40C
Separation pressure 6 bara
Flow 100 kg/s

What if we selected backpressure instead?

Example, back pressure
 Example, back pressure
The maximum power will be 6,4 MW
Entalpy = 1200 kJ/kg
Separation pressure 12 bara
Flow 100 kg/s
 Example
Optimum separation pressure is 6 bara, is that
ok?
Saturation temperature for 1200 kJ/kg is 273C
1400
quartz solubility (F&P82)

1200 amorphous silica solubility (F77)

1000
SiO2 (mg/kg)

800 330 C

300 C
600
270 C

400 240 C

200

0
1.00 10.00 100.00
Pressure (bar-a)
 Thank You!
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