Techno-Economic Analysis of ORC in Gas Compression Stations Taking Into Account Actual Operating Conditions

Gas compressor stations represent a huge potential for exhaust heat recovery, currently under-exploited. Typical installations consist of multiple gas turbine units in mechanical drive arrangement, operated, most of the time, at part-load conditions and with limited conversion efficiency. In this context, this paper investigates the energetic-economic potential of ORC application in typical gas compression facilities, as innovative contribution with respect to literature. The ORC is designed to convert the gas turbines wasted heat into useful power. Additional power output can be used either inside the compression facility, reducing the amount of consumed natural gas and, consequently, the environmental impact, or delivered to the electrical grid. Taking into account real operation of gas turbines in a natural gas compression station, located in North America, additional generated energy and CO2 avoided, thanks to ORC operation, are quantified. Two ORC arrangements, namely with and without intermediate heat transfer fluid, are proposed and the design performance are identified. Influence of topper cycle part load operations on bottomer section are quantified through an off-design thermodynamic evaluation. The goal of the performed analysis is to obtain a detailed scenario of the integrated system operation on yearly basis. Results, for a reference 50 MW compression station, show that the direct heat exchange configuration guarantees up to 66 GWh/year of additional electrical energy, saving up to 36*103 tons/year of CO2, while ORC investment costs can be recovered within 7 years of operation. The performed comprehensive investigation assesses the ORC as a techno-economic profitable technology to recover wasted heat in natural gas compression facilities.