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

Vapor

2 phase flow

Turbine
Phigh

Generator

Steam
separator
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

400

300

200

100

0
1,2

0,8

0,6

Turbine outlet pressure [bara]

0,4

0,2

Turbine Power [kJ/kg]

500

Steam Power Plant with Condenser

Silencer
Steam

Geothermal
fluid

Turbine

Generator

G
Steam
separator

Mist
eliminator

Cooling tower

Production wells
Gas Extraction System
Condenser

Water

Condensate
Condensate
Reinjection wells

Steam Power Plant Double Pressure

Two phase
flow

Steam
separator

HP steam

Turbine - generator

LP steam

Two
phase
flow

LP Steam
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
separator

Secondary steam

LP Turbine - generator

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
heating
system

To district
heating

Condenser
Tcw
Cooling system

Production wells Reinjection wells

Freshwater wells

District heating plant

Process Flow Diagram

Well head silencers

Steam separators
Two phase flow

Mist separators
Steam
Pressure
regulation

Generators
Turbines

Cooling
towers
Production wells

Condensers

Geothermal water

Cold water pump

Geothermal water
emergency exhaust

Condensers

De-aerators

Hot water tank

De-aerators

25. 02. 2008

Re-injection wells
Heat exchangers

Binary Cycles
Phigh

Turbine

Generator

Tsource
Evaporator
Tdischarge

Plow

Condenser

Tcw
Cooling system

Circulation pump

Binary Cycles with Recuperation

Phigh

Turbine

Generator

Tsource
Evaporator
Tdischarge

Plow

Recuperator

Condenser

Tcw
Cooling system

Circulation pump

Binary Plant Berlin El Salvador

LaGeo

Binary Cycles Kalina

Separator
Turbine

Tsource
Evaporator

High temp
recuperator

Generator

Tdischarge

Low temp
recuperator

Condenser

Tcw

Cooling system

Circulation pump

Hsavik Kalina plant

ORC

Kalina
12 0

14 0

11 0

12 0

Temperature

10 0

Temperature

10 0

80

90

80

60

70

40

60

20
55 0

50 0

45 0

40 0

35 0

30 0

25 0

20 0

50
0

Heat transfer

0, 2

0, 4

0, 6

Heat Transfer

0, 8

Binary Cycles Kalex

Tsource

Tdischarge

Cooling system

Work Cycle Comparison

Specific Power

Work Cycle Cost Comparison

12

10

/W

Kalina

Kalex
ORC

0
80

85

90

95

100

105

110

Inlet Temperature [C]

115

120

125

130

Steam supply system

Turbine - generator

Primary binary
turbine - generator

Secondary binary
turbine - generator
Evaporator

Cooling system
Production wells

Reinjection wells

Cooling system

Demonstration of model
Turboden ORC model:
http://www.turboden.eu/en/rankine/rankinecalculator.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
Two phase flow

Mist separators
Steam

Generators

Turbines

Production wells

Geothermal
water

Re-injection wells

Pressure
relief

emergency exhaust

Cooling
towers

Condensers

Nesjavellir Power Plant

Cooling towers

Power
Plant

Steam
pipelines

Production Two phase

flow
Well
Steam vent
station
Separation
station

Gathering system- Design

Design standards
Standards i.e.
Pressure directive
97/23/EC

Pressure selection

Chemical constraints
Power generation
Productivity curves

quartz solubility (F&P82)

amorphous silica solubility (F77)

1200

1000

SiO2 (mg/kg)

1400

330 C

800

300 C
600

270 C
240 C

400

200

0
1.00

10.00

Pressure (bar-a)

100.00

Chemical constraints
Scaling
Corrosivity
Radioactivity
Mitigation:
Pressure control / closed loop system
cleaning of the steam
Inhibitors

Power generation

500

Assumptions:
Total turbine efficiency: 0,8

450

Turbine power [kJ/kg]

400

h = 2200 kJ/kg

350

h = 2000 kJ/kg

300
h = 1800 kJ/kg

250
h = 1600 kJ/kg

200

150
100
50
0

10

12

Separator pressure [bara]

14

16

18

20

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

Pipe diameter [mm]

900

800

700

7 bar-a

600

20 bar-a
500

400

300

20

40

60

80

100

Flow [kg/s]

120

140

160

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)

amorphous silica solubility (F77)

1200

SiO2 (mg/kg)

1000

330 C

800

300 C
600

270 C
240 C

400

200

0
1.00

10.00

Pressure (bar-a)

100.00

Thank You!
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