ORC technology for low and high temperature

Transcription

1 Jahrestagung des ORC-Fachverbandes e.v. 24 th September 2012, Bayreuth ORC technology for low and high temperature

2 Agenda Company introduction / What we do Geothermal Industrial Heat Recovery Some reference cases 2

3 Company Introduction 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, former Professor of Energy at the University Politecnico di Milano, and today the 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: 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 Pratt & Whitney (UTC Corp.), a worldwide leader in development, production and service for aero engines, aerospace drive systems and heavy duty gas turbines. Today Turboden is part of Pratt & Whitney Power Systems (PWPS), to develop ORC solutions from renewable sources and waste heat worldwide. 3

4 What We Do Biomass Geothermal electricity heat Solar Waste-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 from kw kw to to 6 10 MW MW customized solutions up up to to MW MW 4

5 TEMPERATURE The Thermodynamic Principle: the ORC Cycle 3 4 Turbine Generator Evaporator FLUID CIRCUIT Preheater Condenser COOLING CIRCUIT HEAT Pump The turbogenerator uses the geothermal water to pre-heat and vaporize a suitable organic working fluid in the evaporator (2 3 4). The organic fluid vapor powers the turbine (4 5), which is directly coupled to the electric generator through an elastic coupling. The vapor is then condensed in the condenser, cooled by water or air (5 1). The organic fluid liquid is finally pumped (1 2) to pre-heater and evaporator, thus completing the sequence of operations in the closed-loop circuit. 5

6 Geothermal ORC Design Main issues to consider Corrosion special and costly materials for the heat exchangers great influence on the cost of the unit longer delivery period Scaling limits in cooling the geothermal brine Fouling removable covers and straight cleanable tubes Working fluid flammability: critical in urban areas & for insurance cost Cascade use / cogeneration: schemes, feasibility Vapor plume and need for makeup water in case of evaporative devices Larger footprint and noise emissions from the fans in case of air cooling 6

7 Geothermal ORC Design Evaluation of the proper Cooling System: wet Vs dry WATER CONDENSERS EVAPORATIVE TOWERS EVAPORATIVE CONDENSERS AIRCOOLERS AVAILABLE MAKE UP WATER NOT AVAILABLE Evaporative towers Smaller footprint Efficient in hot dry climate Higher own-consumption Fresh water consumption Chemical water treatment operation cost, environment Air condensers Larger footprint Efficient in cold climate Lower own consumption No water needed Virtually no environmental impact and operating costs AIR CONDENSERS Critical issues Investment costs: initial / overall Generated yearly output, linked to gross power and parasitic loads 7

8 Geothermal ORC Design Working fluid selection is influenced by many factors Cost Enthalpy drop & flow rate Pressure levels Environmental friendliness Heat input curve Cooling system Flammability OPTIMAL FLUID Option to select a non flammable fluid Fluid flammability is critical in urban areas & for insurance costs Turboden identified and studied a number of fluids Turboden tested a non flammable fluid in Altheim, being used ever since Lab tests under way to check compatibility & behavior in wider range Possibility to place the unit inside a building or shelter (protection from atmospheric agents and mitigation of noise emissions) changes from case to case The Altheim plant building 8

9 Sauerlach Plant type: Two level cycle geothermal unit, indoor Customer: SWM - StadtWerke München (public utilities company) Location: Bavaria, Germany Commissioning expected: 4 rd Quarter 2012 Heat source: geothermal fluid at 140 C Cooling device: Air Cooled Condenser Total electric power: 5+ MW el plus thermal decoupling for district heating Working fluid: refrigerant (non flammable) 9

10 Dürrnhaar and Kirchstockach 5.6 MW plants under construction Customer: Hochtief Energy Management GmbH Location: Dürrnhaar and Kirchstockach (München) Number of Power Plants under construction: 2, outdoor Electric power: 2 x kw Cooling device: Air Cooled Condenser Commissioning expected: 4 rd Quarter

11 H-REII DEMO Project GOALs: a) To realize an integrated fumes depuration and heat recovery system a) To develop policy and governance actions for reducing CO 2 emissions by valorisation of process effluents in Energy Intensive Industries For more information :

12 power MW HREII Demo project: first EU estimates Total: 629,5 200 Steel: 376, Cement: 145,8 Sectors Glass: 107,1 Power to recovery in Europe (first estimation): 630 MWe from 3,2 TWh/y to 5 TWh/y EU MSs considered in the analysis: Italy, Germany, France, Spain, UK and Belgium ( 95% of European production in the three areas examined ) + Austria, Czech Rep.

13 Steel (EAF) : Riesa ESF Feralpi project Project: Feralpi Germany Reference Case study: Electric Arc Furnace waste heat recovery Heat source: exhaust gas at C Cycling behavior of heat source Saturated steam heat recovery loop ORC system automatically follows the EAF melting cycle ORC electric power: ~ 3 MWe Final Client: Feralpi Stahlhandel Client engineer : Tenova Start up: expected for II quarter

14 Cement: Ait Baha - Italcementi Project Reference Case study: PRS gas waste heat recovery Clinker production capacity: ton/day Heat source: exhaust 330 C Gas cooled down to 220 C (extra heat used for raw material pre heating) Thermal oil heat recovery loop ORC electric power: ~ 2 MWe Client: CIMAR ITALCEMENTI GROUP (Morocco) In operation since IV quarter 2010 July 2012 achieved 10,000 operating hrs with 98,5 % availability 14

15 Cement: Alesd Holcim Romania Project Project Holcim Romania Reference Case study: PRS and CC gas waste heat recovery Romania Clinker production capacity: ton/day Heat source: exhaust 360 C (PRS) and hot 250 C (CC) Thermal oil (PRS) and pressurised water (CC) heat recovery loops ORC electric power: ~ 4 MWe Client: Holcim Romania Holcim Group (Romania) Unit in operation since Q beginning of September achieved 1,000 operating hrs ORC plant PH boiler AQCboiler 15

16 Cement: Rohoznik Holcim Slovakia Project Slovakia Project Holcim Slovakia Reference Case study: PRS and CC gas waste heat recovery Clinker production capacity: ton/day Heat source: exhaust 360 C (PRS) and hot 310 C (CC) Thermal oil heat recovery loops ORC electric power: ~ 5 MWe Client: Holcim Slovakia Holcim Group (Slovakia) Under Construction; start up expected in II quarter

17 Refractory material: Radenthein RHI project Project RHI Austria Reference Case study: Refractory ovens exhaust gas heat recovery Refractory production capacity: 250 ton/day Heat source: exhaust 500 C Gas cooled down to ca. 150 C Thermal oil heat recovery loop ORC electric power: ~ 1 Mwe Client: RHI GROUP (Radenthein - Austria) In operation since I quarter

18 Glass: Cuneo AGC project Project AGC Italy Reference Case study: Float glass production process waste heat recovery Glass production capacity: 600 ton/day Heat source: exhaust gas at approximately 500 C Thermal oil heat recovery loop ORC electric power: ~ 1,3 MWe Final Client: AGC Glass Europe Cuneo Plant General contractor: GEA Bischoff In operation since I quarter 2012 Electric efficiency: 24 % 18

19 Steel (rolling mill): Singapore Natsteel project Project Natsteel Singapore Reference Case study: rolling mill preheating furnace waste heat recovery Heat source: exhaust gas from LFO 400 C Direct exchange between exhaust gas and working fluid ORC electric power: ~ 0,7 MWe Client: Natsteel Tata Group Under Construction; start up expected in I quarter

20 Heat Recovery from Waste Incineration plant Example of Turboden tailor-made ORC plant for heat recovery from hot water: 3 MWe installation in Roeselare (B) Plant type: Heat recovery from pressurized water boiler in waste incinerator Customer : MIROM (Roeselare-Belgium) In operation since: II quarter 2008 Heat source: hot water at 180 C (back 140 C) Cooling source: water/air Total electric power: 3 MW el Net electric efficiency: 16,5% Availability: > 98% 20

21 Waste gasification: Ankara Turkey project Project ITC Turkey Reference Case study: waste refusal gasification waste heat recovery Heat source: exhaust gas from syngas C Thermal oil heat recovery loop ORC electric power: ~ 5,5 MWe ORC gross electric efficiency: 26 % Client: ITC Under Construction; start up expected in II quarter

22 APG (Flare gas): Russia project Project Russia flare gas Reference Case study: flare gas burning waste heat recovery Heat source: exhaust gas from flare gas C Thermal oil heat recovery loop ORC electric power: ~ 2 MWe Client: Undisclosed Under Commissioning 22

23 Bottom cycle in small combined cycles power plants At present totally 13 projects are either in operation or under construction for heat recovery from reciprocating engines (HFO, LFO, CPO, natural gas, landfill gas, syngas, etc) and gas turbines (e.g. gas compressor stations) for sizes between 200 kw up to 4,5 MW. Engine Exhaust Thermal Power WHOH Thermal Oil Subsystem ORC Powerplant Dissipated Heat Cooling Subsystem ORC Turbogenerator ORC Electricity 23

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25 Thank you for your attention! For more information: Giorgio Za Sales Manager Biomass Department Turboden s.r.l. Via Cernaia, Brescia, Italia tel fax info@turboden.it C.F./P.I. IT capitale sociale i.v. R.I.: C.C.I.A.A. di Brescia REA