Extensive techno-economic assessment Combined Inverted Brayton – Organic Rankine Cycle for High-Temperature Waste Heat Recovery Structural integration of two thermodynamics cycles: inverted Brayton (IBC) and organic Rankine (ORC), enables two use the proposed technology with high efficiency for waste heat recovery in a wide spectrum of high-temperature exhaust sources. Current stage: a submission is under minor revision in Energy Conversion and Management journal (Scopus CiteScore 2017: 6.85) ([Abrosimov et al., 2019]). An initial market analysis was performed. Patenting potential: 1) Useful model. The basic idea was disclosed in 2010, but specific configuration is patentable to the best of our knowledge; 2) Patent of a close idea specifically oriented on internal combustion engines, which currently is also under development. End-users: 1) owners of generating and driving reciprocating engines (capacity 0.5-1.5 MW) including marine Diesel, 2) owners of gas turbines of gas-pumping stations, 3) owners of Diesel driven ships, - who want to receive additional electrical power without changing of the existing facility. Also, heavy-trucks owners may be end-users at further steps. Clients: to be defined: a) end-users, b) engine producers (licensing) Potential partnership with Belgium start-up “Mitis” (Liege University). They have a good component, and experimental base, and experience for the building of the prototype. NDA with them is being processed in Skoltech now. Project end-results: two patents, prototype built in partnership with Liege University, detailed market analysis, 5 potential agreements with potential clients (for scenario a.), 2 potential producers (in case of scenario b.) Extensive techno-economic assessment Kirill Abrosimova Prof. Andrea Bacciolib Prof. Aldo Bischia, b

Outline Problems of ORC in high-temperature WHR Alternative solution studied Case-study and assumptions Choice of working fluid for ORC Benchmarking versus ORC Water condensation issue Ambient temperature effect Efficiency vs. economics Conclusions & Prospects The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

ORC installation trend Heat recovery Crude oil price [USD/bbl] Installed capacity [MW/year] The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy Evolution of installed ORC capacity over time [Tartière, Thomas, and Marco Astolfi. "A world overview of the organic Rankine cycle market." Energy Procedia 129 (2017): 2-9]

Problem statement. 1 Tmax1 – working fluid temperature limit Tmax2 Temperature, K ` ∆T Tmax2 Tmax1 Exhaust temperature (450 – 800 oC) Entropy, J/kg∙K Tmax1 – working fluid temperature limit Tmax2 – intermediate fluid temperature limit ∆T emphasizes unused thermodynamic potential. The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Outline Problems of ORC in high-temperature WHR Alternative solution studied Case-study and assumption Choice of working fluid for ORC Benchmarking versus ORC Water condensation issue Ambient temperature effect Efficiency vs. economics Conclusions & Prospects The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Investigated solution Combined inverted Brayton – organic Rankine cycle (IBC+ORC) Entropy, J/kg·K Temperature, K The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Investigated solution Combined inverted Brayton – organic Rankine cycle (IBC+ORC) Entropy, J/kg·K Temperature, K The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Problem statement. 2 Temperature, K Entropy, J/kg∙K The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy [Yue, Chen, Dong Han, and Wenhao Pu. "Analysis of the integrated characteristics of the CPS (combined power system) of a bottoming organic Rankine cycle and a diesel engine." Energy 72 (2014): 739-751.]

Problem statement. 2 Increased engine backpressure causes the decrease of the engine power. Temperature, K Entropy, J/kg∙K The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy [Yue, Chen, Dong Han, and Wenhao Pu. "Analysis of the integrated characteristics of the CPS (combined power system) of a bottoming organic Rankine cycle and a diesel engine." Energy 72 (2014): 739-751.]

Problem statement. 2 Increased engine backpressure causes the decrease of the engine power. It may cause a violation of engine operating conditions; hence, warranty issues are possible. Temperature, K Entropy, J/kg∙K The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy [Yue, Chen, Dong Han, and Wenhao Pu. "Analysis of the integrated characteristics of the CPS (combined power system) of a bottoming organic Rankine cycle and a diesel engine." Energy 72 (2014): 739-751.]

Outline Problems of ORC in high-temperature WHR Alternative solution studied Case-study and assumptions Choice of working fluid for ORC Benchmarking versus ORC Water condensation issue Ambient temperature effect Efficiency vs. economics Conclusions & Prospects The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Case-study and assumptions I-D Aspen Hysys simulation Pre-design optimization Gas-fired ICE 1400 kW Nominal Texhaust: 520 oC Main assumptions: Pressure losses: relative pressure drop Minimal pinches: 5-30 oC Turbomachinery efficiency adjustment Air cooling: 17 W/kWh The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy System efficiency:

More assumptions Evaporation-condensation temperature limit [ ] – feasibility limitation for one stage radial turbine. ES: Peng-Robinson for ORC fluids, Refprop for exhaust gas Expander and pump efficiency: 80% Generator efficiency: 96% Min gap till critical temperature: 15 oC Condenser pinch: 5 oC; Evaporator pinch: 15 oC Superheating: 5-40 oC The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy [Quoilin, Sylvain, et al. "Working fluid selection and operating maps for Organic Rankine Cycle expansion machines." Proceedings of the 21st international compressor conference at Purdue. 2012.]

Outline Problems of ORC in high-temperature WHR Alternative solution studied Case-study and assumptions Choice of working fluid for ORC Benchmarking versus ORC Water condensation issue Ambient temperature effect Efficiency vs. economics Conclusions & Prospects The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Choice of ORC working fluid Power and system efficiency of ORC and ORC Reg [*] The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy *[Abrosimov, K.A., Andrea Baccioli A, and Bischi A. "Techno-economic analysis of combined inverted Brayton–Organic Rankine cycle for high-temperature waste heat recovery." Energy Conversion and Management: X 3 (2019): 100014.

Outline Problems of ORC in high-temperature WHR Alternative solution studied Case-study and assumption Choice of working fluid for ORC Benchmarking versus ORC Water condensation issue Ambient temperature effect Efficiency vs. economics Conclusions & Prospects The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Benchmarking and comparison System efficiency of ORC, ORC Reg, CS, and CS Reg for 470, 520, and 570 oC temperature of exhaust: The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Benchmarking and comparison + sensitivity The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy Effect of change in assumed parameters on the system efficiency of ORC Reg and CS Reg. System efficiency of ORC, ORC Reg, CS, and CS Reg for 470, 520, and 570 oC temperature of exhaust

Outline Problems of ORC in high-temperature WHR Alternative solution studied Case-study and assumption Choice of working fluid for ORC Benchmarking versus ORC Water condensation issue Ambient temperature effect Efficiency vs. economics Conclusions & Prospects The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Water condensation effect Gross The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy IBC performance. Influence of water condensation. [*]

Outline Problems of ORC in high-temperature WHR Alternative solution studied Case-study and assumption Choice of working fluid for ORC Benchmarking versus ORC Water condensation issue Ambient temperature effect Efficiency vs. economics Conclusions & Prospects The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Sensitivity from ambient temperature The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy System performance for different ambient temperatures

Sensitivity from ambient temperature With the increase of ambient temperature in the range from 5 to 35oC, the efficiency of the system goes down from 14.6 % to 10.3 %, The decrease is not proportional; the share of IBC part is depreciating. Decrease of system efficiency is slightly non-linear. The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy System performance for different ambient temperatures

Outline Problems of ORC in high-temperature WHR Alternative solution studied Case-study and assumption Choice of working fluid for ORC Benchmarking versus ORC Water condensation issue Ambient temperature effect Efficiency vs. economics Conclusions & Prospects The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

LCOE vs efficiency. Pareto fronts Levelized cost of energy: Module costing technique [Turton, 2008] Pareto fronts based on pre-design MO optimization The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

LCOE vs efficiency. Pareto fronts The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy Pareto front for LCOE-efficiency pair and optimal pressure ratio of the IBC turbine. Tamb=20 oC.

Conclusions With the increase of Tamb (5 to 35oC), the ηsys decreases (14.6 to 10.3 %) The decrease is not proportional; the share of IBC part is depreciating. A recommended configuration resulted from two-objective optimization suggests ηsys =12.11 % and LCOE = 162.4 $/MWh. Temperature before the compressor (driven by Tamb) changes the shape of IBC power-pressure ratio curve. It affect optimization results, and should be considered. Condensation does not occur above certain temperature before the compressor. The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Prospects Further study of the water condensation issue considering sulfur contaminants in the exhaust gas for other fuels Economics of combined heat and power application. Component study and design. The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy

Many thanks for attention! Your comments, feedback, ideas, suggestions are welcome! Contact details: kirill.abrosimov@skolkovotech.ru; +7 905-743-90-91

LCOE vs efficiency. Summary Parameter 470 oC  520 oC 570 oC  η optimization η, % 11.13 12.49 13.74 LCOE, $/MWh 191.5 172.7 156.8 LCOE optimization 9.63 11.43 10.9 182.1 159.3 142.8 Recommended configuration 12.11 13.24 Net power, kW 122.6 147.1 172.9 185.0 162.4 145.3 Cap.cost, $/kW 12 420 10 910 9 760 PR, - 2.24 2.53 2.79 LCOE increase with growth of the efficiency approaching the maximum of efficiency. A recommended configuration was found based on the two-objective optimization with ηsys =12.11 % and LCOE = 162.4 $/MWh for nominal Texhaust Capital investments might be a driver for choice of configuration The proposed solution may suggest an additional electrical power in case of the power consumption growth but with the “old” facility still well-operating. Also, the solution may be benefit-driven, mostly for the European market where the private electricity selling to the grid is much more common than in Russia. In comparison with the main alternative, the organic Rankin cycle (ORC), the solution provides: - higher efficiency (approx. + 15% (relative)); - no impact on the primer engine due to IBC. “Install it nearby and get power”; - better economic parameters (LCOE* = 160 $/MW vs. 172 $/MW for ORC). [Abrosimov et al., 2019] *Levelized Cost of Energy