Experience and progress with ORC turbogenerators in Australia including the new kw e units

Transcription

1 Experience and progress with ORC turbogenerators in Australia including the new kw e units Carlo Minini 10 th Bioenergy Business Breakfast Doc.: rev.0 Date: 23/05/2014

2 About Us Turboden is a leading European company in development and production of ORC (Organic Rankine Cycle) turbogenerators. This state of the art equipment generates heat and power from renewable sources and heat recovery in industrial processes. The company was founded in 1980 in Milan by Mario Gaia, Professor of Energy at the Politecnico di Milano, and today Managing Director of Turboden. His close connection with the university has always ensured the recruitment of highly qualified R&D personnel. Turboden has always had a single mission: to design ORC turbogenerators for the production of heat and electrical power from renewable sources, while constantly striving to implement ORC technical solutions. In 2009, Turboden became part of UTC Corp., a worldwide leader in development, production and service for aero engines, aerospace drive systems and power generation gas turbines, to develop ORC solutions from renewable sources and waste heat worldwide. In 2013 UTC exits the power market forming strategic alliance with Mitsubishi Heavy Industries. In 2013 Mitsubishi Heavy Industries acquires from UTC Pratt & Whitney Power Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are MHI group companies to provide a wider range of products and services for thermal power generation systems. In 2013 Turboden s Quality Management System gets certified to ISO 9001:

3 Over 30 Years of Experience kw e ORC turbogenerator for a solar plant in Australia MW e ORC turbo-generator for heat recovery on a waste incinerator in Belgium kw e ORC turbogenerator for a biomass plant in Italy kw e ORC geothermal plant in Zambia 2009 First 100 plants and first installed 100 MW e 2010 First plant overseas 2014 Over 250 ORC plants in the world and back to Australia 3

4 Turboden strong points R&D Sales/marketing Design Operations & manufacturing Aftermarket service Participation in national & EU research programs Cooperation with EU Universities and Research Centres Thermodynamic cycle optimization Working fluid selection & testing Thermo-fluid-dynamic design and validation Implementation & testing of control/ supervision software Pre-feasibility studies: evaluation of technical & economical feasibility of ORC power plants Customized proposals to maximize economic & environmental targets Complete in-house mechanical design Proprietary design and own manufacturing of ORC optimized turbine Tools: - Thermo-fluiddynamic programs - FEA - 3D CAD-CAM - Vibration analysis Outsourced components from highly qualified suppliers Quality assurance & project management In house skid mounting to minimize site activities Start-up and commissioning Maintenance, technical assistance to operation and spare parts service Remote monitoring & optimization of plant operation 24/7 remote assistance available Many patents obtained 4

5 What We Do Biomass Geothermal Solar Waste-heat heat electricity heat Turboden designs and develops turbogenerators based on the Organic Rankine Cycle (ORC), a technology for the combined generation of heat and electrical power from various renewable sources, particularly suitable for distributed generation. standard units from 200 kw to 15 MW customized solutions up to 20+ MW 5

6 The Thermodynamic Principle: The ORC Cycle The turbogenerator uses the hot temperature thermal oil to pre-heat and vaporize a suitable organic working fluid in the evaporator (8 3 4). The organic fluid vapor powers the turbine (4 5), which is directly coupled to the electric generator through an elastic coupling. The exhaust vapor flows through the regenerator (5 9) where it heats the organic liquid (2 8). The vapor is then condensed in the condenser (cooled by the water flow) (9 6 1). The organic fluid liquid is finally pumped (1 2) to the regenerator and then to the evaporator, thus completing the sequence of operations in the closed-loop circuit. 6

7 ORC Plants Performance 100% Thermal power from thermal oil (or other heat carrier) 18 to 24% 2% 80 to 74% Thermal power to heat users Gross electric power Thermal losses (insulation and generator losses) Gross electric efficiency: up to 24% and more Overall energy efficiency: 98% 7

8 ORC Plant in a Process of Cogeneration from Biomass 8

9 Why High Molecular Mass Working Fluid Instead of Water? WATER Water Small, fast moving molecules Metal parts and blade erosion Multistage turbine and high mechanical stress HIGH MOLECULAR MASS FLUID Organic Fluid Very large flow rate Larger diameter turbine No wear of blades and metal parts 9

10 Advantages of Turboden ORC Turbogenerators Technical advantages High cycle efficiency Very high turbine efficiency (up to 90%) Low mechanical stress of the turbine due to the low peripheral speed Low RPM of the turbine allowing the direct drive of the electric generator without reduction gear No erosion of blades, thanks to the absence of moisture in the vapor nozzles Operational advantages / results Simple start-stop procedures Automatic and continuous operation No operator attendance needed Quiet operation Partial load operation down to 10% of nominal power High efficiency even at partial load Low O&M requirements: about 3-5 hours / week Long life High Availability (confirmed by more than 4 million hours of operation) 10

11 Turboden ORC Plants in the World > 200 biomass applications in 26 countries 11

12 What we have done up to now* 281 Turboden ORC References in the World in 32 Countries 246 applications in biomass in 26 Countries By applications: By sizes: District heating From 200 kwe to 3 MWe < 400 kwe 7-43 Sawmills and wood industry From 600 kwe to 6.5 MWe MWe MDF (Medium Density Fiber) From 1 MWe to 1.3 MWe 1 MWe power only (12HRS) Pellet industry From 600 kwe to 2 MWe 1-2 MWe 82-5 Public buildings: CCHP (Combined Cooling Heating Power) - 15 CHP In industrial processes (Agroindustry, Wood industry,..) From 600 kwe to 1.8 MWe 2-5 MWe 26 From 200 kwe to 1.3 MWe > 5 MWe Power Only 12 HRS: 1 MWe Pure Cycle 3 * May 2014

13 Solid biomass CHP applications with ORC some CHP applications District heating Sawmills - wood industry size range MWe MWe Fuels MDF Pellet industry CCHP Public buildings / Industrial processes Wood biomass: sawdust, woodchips, bark, treated wood Other biomass: dried sewage sludge, green cuttings, rice husks, oat husks, olive husks, vinasse and vine cuttings, etc. Waste material (municipal or industrial solid waste) MWe MWe MWe Heat Consumers District Heating networks Timber drying in sawmills Sawdust drying in wood pellet factories MDF/PB Producers Air pre-heating in MDF industry Refrigeration, trigeneration (chillers) Greenhouses Wine industry

14 Waste to Energy Reference Plant ITC, Turkey Location: Ankara (Turkey) Client: ITC-KA Enerji Uretim Sanayi Ve Ticaret A.S. Start-up: Q Heat source: industrial waste gasification Source temperature: 315 C (thermal oil) Water temperature (in/out): C Electric Power: 5.5 MW e Net electrical efficiency: 25% Project description: the high efficiency Turboden 55-HRS unit exploits the heat from the combustion of the synthesis gas generated from industrial waste. The gas is burned in a boiler that heats up the thermal oil that carries the 20 MWt input into the ORC module. The cooling is done through wet cooling towers. The client is installing a second 55-HRS unit and is looking at a number of 110-HRS units ( 11 MW el each) to use with municipal waste in the near future 14

15 Reference Plant MSG, WA Location: Wagin (WA) Client: Morton Seed and Grain Start-up: Q Heat source: oat husks Source temperature: 23 bar(a) saturated steam Water temperature (in/out): C Electric Power: 600 KW e Net electrical efficiency: 17% Project description: The proposed facility will convert between 6,000 and 10,000 tons of oat husk per year. The Turboden 6 HR split unit will be fed with saturated steam instead of the traditional thermal oil and will be used at part load (60-80%) most of the time for a couple of years, taking advantage of its ability to follow variable loads and retain high part load efficiency (e.g. at 50% load, around 90% of the nominal load efficiency). The estimated project value of about AU$3.8 Million. 15

16 New Turboden 2 and Turboden 3 Dual Mode Layout: compact, containerised Dual Mode: Power only or CHP Heat carrier: thermal oil or saturated steam Inlet temperature: 200 to 310 C Water temperature (in/out): to C Gross Electric Power: 200 to 300 KW e Gross electrical efficiency: 12.5 to 17.5% 16

17 New Turboden 2 and Turboden 3 Dual Mode 17

18 Back-up slides 18

19 Waste to Energy Reference Plant n.1 Mirom, Belgium 1/2 Plant type: heat recovery from pressurized water boiler in urban waste incinerator Customer: MIROM Location: Roeselare, Belgium In operation since: II quarter 2008 Availability: > 98% Heat source: hot water at 180 C (return at 140 C) Cooling source: water/air Total electric power: 3 MW Net electric efficiency: 16.5% Non flammable working fluid: to meet customer s requirement 19

20 Waste to Energy Reference Plant n.1 Mirom, Belgium 2/2 Initial installation in operation since: 1976 Treatment capacity: ton/year urban waste Boilers: 2x 8MW th Use of heat: hot water at 180 C (return at 140 C) District heating since: 1986, 21 customers, 7.5 km ORC project started: 2006, in operation since 2008 in parallel to district heating use Before After 20

21 Biomass References Pellet process and Turboden ORC integration Industrial process productivity needs ORC Flexibility and Reliability Pellet Manufacturing Process The integration between the Turboden ORC and an existing or brand new Pellet manufacturing process gives the possibility to diversify the business producing, at the same time, Pellet and Electrical Energy from Renewable Sources (i.e. biomass) 21

22 Biomass References Dimensioning Parameters Source: Bioenergy International May 2011, Prodesa Medioambiente Cogeneracción y producción de pellet ORC Size Turboden 10 CHP Split (4,100 kwth) Turboden 14 CHP Split (5,340 kwth) Turboden 22 CHP Split (9,598 kwth) Pellet production capacity** 30,000 t/y* 42,000 t/y* 85,000 t/y Turboden 30 CHP Split (13,636 kwth) 120,000 t/y Sample case:** ORC Unit: Turboden 10 CHP integrated in a Pellet plant Pellet production capacity = 4 tons/h Pellet production = 30,000 tons/y Biomass Consumption = 57,500 tons/y Boiler installed = 5.2 MWth Electrical power installed = 1 MWel Thermal power output = 4.1 MWth at 60/80 C **Assuming Turboden CHP and Belt dryer configuration 22

23 Biomass References Example of Pellet application Mudau in Germany - MU Model: T1100 Client: BIO-ENERGIE MUDAU GMBH & CO.KG Start up: June 2006 Location: Mudau - Germany Fuel: Wood chips Electric power: 1,187kWe Thermal Use: drying belt in pelletisation process Thermal power: 5,335kWth Water Temperature: C Boiler supplier: Kohlbach Context / Special Feature A/ Pelletisation process - Max pellet production: 6t/h - Hot water to dry saw from 50% to 10% B/ Specificity: Application Pellet - Biomasse boiler: 6570 kwth - Cogénération withorc: 5,335kWth 1,187 kwe (brut); 1,124 kwe (net) - belt dryer supplier: Stela - Pelletisation system supplier: Salmatec

24 Combined Heat & Power (CHP) with Split system Standard Sizes and Typical Performances 24

25 HRS High Electrical Efficiency Units 25

26 HRS High Electrical Efficiency Units 26