Innovation Accelerator’s client DRD Power Ltd gave a presentation on their work in developing a demonstrator unit which produces electricity from waste heat. The unit can extract energy from low grade heat sources (90-130oC) typically found on many chemical processing plants. This heat has up until now been uneconomic to process, however, DRD Power’s excellent work means a robust capability now exists in which electricity can be extracted from low pressure steam or waste water streams, even those containing contaminants.

The presentation at Teesside University on 24th November was hosted by the Institute of Measurement and Control, and was well received by the audience prompting a long discussion section. Roger Mallinson of DRD Power explained the processes, some of the problems which were overcome and the technical specification of the plant.

The demonstrator unit is presently undergoing testing at Hunstman Tioxide in Greatham, and a full technical feasibility assessment will be concluded at the end of 2011. Early results have been very encouraging, with electricity produced from waste heat at temperatures as low as 78oC. Energy is converted from heat to electricity through the Organic Rankine Cycle which, although it is a well known process, operating efficiently at these temperature levels is a major achievement.

A 200kW rated ORC unit is able to produce electricity worth £100,000, equivalent to CO2 savings of 700T per annum. Part sponsored by The Carbon Trust and ONE, DRD Power have recently being given an IChemE – Highly Commended award for innovation and excellence. DRD Power intend to build and develop similar units based on the knowledge gained from this demonstrator.

Many industries are potential clients, so anyone with a waste heat stream between 90-130oC on part of their process should contact DRD Power and visit the demonstrator.