Il progetto WHAVES. Progetto di dissemination e finanza. promozione best practices modellistica modelli innovativi di finanziamento

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1 Il progetto WHAVES Progetto di Policy ~ 100 audit energetici in aziende energivore Policy nazionale Progetto DEMO Impianto di recupero di calore da EAF Feralpi Policy europea Progetto di dissemination e finanza promozione best practices modellistica modelli innovativi di finanziamento

2 Turboden s ORC Technology for Steel & Metals Made In Steel 20 maggio 2015

3 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, Associate Professor at Politecnico di Milano, teaching Thermodynamics, Renewable Energy and specifically studying ORC systems. At present Prof. Gaia is Honorary Chairman. A number of his former students are key persons in the Company and the whole Company is permeated by innovative and research oriented spirit. 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 9001:2008.

4 35 Years of Experience Prof. Mario Gaia makes experience in the field of ORC within his research group at Politecnico di Milano 1976 First prototype of a solar thermodynamic ORC Prof. Mario Gaia founds Turboden to design and manufacture ORC turbogenerators Turboden develops research projects in solar, geothermal and heat recovery applications 1998 First ORC biomass plant in Switzerland (300 kw) Turboden installs ORC biomass plants, especially in Austria, Germany and Italy Turboden plans to enter new markets, with focus on North America First heat recovery applications 2009 Turboden achieves 100 plants sold United Technologies Corp. (UTC) acquires the majority of Turboden s quota. PW Power Systems supports Turboden in new markets beyond Europe UTC exits the power market forming strategic alliance with Mitsubishi Heavy Industries PW Power Systems becomes an MHI group company MHI acquires the majority of Turboden. Italian partners stay in charge of management Today - Over 300 ORC plants in the world, over 240 in operation

5 35 Years of Experience kw el ORC turbo-generator for a solar plant in Australia MW el ORC turbo-generator for heat recovery on a waste incinerator in Belgium kw el ORC turbogenerator for a biomass plant in Italy kw el First heat recovery application at Italian foundry 2009 First 100 plants and first installed 100 MW el 2010 First plant overseas 2015 Over 300 ORC plants in the world

6 Turboden a Group Company of MHI Energy & Environment the largest segment of MHI over $12 billion (in fiscal 2013) Mitsubishi Heavy Industries is one of the world's leading heavy machinery manufacturers, with consolidated sales of over $32 billion (in fiscal 2013). Foundation July 7, 1884 Energy & Environment Providing optimal solutions in the energy-related fields of thermal power, nuclear energy and renewable energy in different environmental areas and for Chemical plants & other industrial infrastructures elements. Commercial Aviation & Transport Systems Delivering advanced land, sea and air transportation systems, including civilian aircraft, commercial ships and transit networks. Machinery, Equipment & Infrastructure Providing a wide range of products that form the foundation of industrial development, such as machine tools, material handling, construction machinery, air-conditioning and refrigeration systems. Integrated Defense & Space Systems Providing advanced land, sea and air defense systems, including naval ships, defense aircraft, launch vehicles and special vehicles, as well as space-related services.

7 Waste heat recovery options in Energy Intensive Industries First option is using residual heat as such in process / plant however Efficient direct use of waste heat is normally limited due to: Overall efficiently can improve converting residual heat to mechanical / electrical power Rankine Cycle systems are most common heat-to-power solutions in Energy Intensive Industries

8 ORC in Industrial Heat Recovery Industrial heat recovery demands Main process reliability must not be affected Plant operators must not be distracted Matching actual working regimes (variable, semi-batch, upset) ORC can guarantee Process interface with easy decoupling Simple, fail-safe, automatic system Flexible / modulating operation + suitable heat capture and transfer systems Key points: Process heat exchangers Heat carrier

9 Heat to power conversion with Rankine Cycle (I) Steam Turbine & ORC Hot source Working fluid Heat sink ORC (Organic Rankine Cycle): a cycle with a change of phase utilizing a working fluid different from water. High molecular mass fluid instead of water / steam Technology of choice for distributed generation in renewables and in heat recovery

10 Heat to power conversion with Rankine Cycle (II) Steam Turbine & ORC Steam Turbine (Traditional Rankine Cycle) vs. Organic Rankine Cycle (ORC) Temperature Temperature Thermodynamic features Operation and maintenance costs Entropy High enthalpy drop Superheating needed Risk of blade erosion Water treatment required High pressures and temperatures Specialized personnel necessary Entropy Small enthalpy drop No need to superheat No risk of blade erosion Non oxidizing working fluid Minimum personnel Automatic/Self regulating Convenient for plants > 10 MWe High flexibility and good Other features Low flexibility performance at partial load Lower performance at partial load Well proven in industrial heat recovery

11 Turboden ORC Plants in the World APPLICATION SIZE MW PLANTS no. MW ORC WORKING FLUID Wood Biomass Siloxanes; Hydrocarbons HEAT CARRIER Thermal oil(258) Saturated steam(1) Geothermal Refrigerants; Hydrocarbons None - Direct exchange Combined Cycle (bottomingof gas turbinesor reciprocating engines) Siloxanes; Hydrocarbons Waste to Energy Industrial Heat Recovery (Cement, Glass, Steel, Aluminium, etc.) Refrigerants;Siloxanes: Hydrocarbons Refrigerants; Siloxanes; Hydrocarbons Thermail oil(9) None Direct Exchange (3) Thermal oil(7) Pressurized water (1) Saturated steam(1) Thermal oil(9) None - Direct exchange(1) Saturated steam(2) Solar thermal power Siloxanes Thermal oil(3) Total Turboden Plants * 420 * 57 presently under construction included Update May 2015

12 Typical ORC Working Fluids

13 Heat carrier loop

14 Typical Heat Carriers in Industrial Applications

15 Five ORC heat recovery installations in Steel and Metals PLANT MAIN PROCESS EQUIPMENT HEAT CARRIER ORC NATSTEEL - Singapore (Start-up: February 2013 ) TYPE CHARGE CAPACITY STEEL ROLLING MILL BILLET RE-HEATING FURNACE Billet 125 ton/h None Direct heat exchange WORKING FLUID GROSS ELECTRIC POWER OUTPUT (kw) NET ELECTRIC POWER OUTPUT (kw) Siloxane ELBE STAHLWERKE FERALPI Riesa, Germany (Start-up: December 2013) UNDISCLOSED CUSTOMER (Expected start up: July 2015) ORI MARTIN Brescia, Italy (Expected start-up: October 2015) STEEL ELECTRIC MELTING FURNACE ALUMINIUM GAS FIRED MELTING FURNACE STEEL ELECTRIC MELTING FURNACE Scrap 3 baskets 100 t Steam -27 bar g 245 C Siloxane 2,700 2,580 Scrap N.A.* Thermal oil 250 C Siloxane 1,706 1,641 Scrap -Consteel 90 t Steam -15 bar g 200 C Siloxane 1,885 1,821 FONDERIA DI TORBOLE Torbole Casaglia, Italy (Expected sart up: First quarter 2016) IRON CUPOLA FURNACE Scrap, pigs 30 ton/h Thermal oil 230 C Siloxane * Not available

16 Reheat furnace heat recovery: Natsteel, Singapore Heat source: Furnace Exhaust gas ORC working fluid: Siloxane Furnace Fuel: Light Fuel Oil Start-up: in operation since February 2013 ORC electric power: 555 kw direct exchange Plant type: Billet re-heating furnace of a wire rod mill Production: 125 t/h (hot charge), 90 t/h (cold charge)

17 EAF Heat Recovery Elbe-Stahlwerke Feralpi Riesa, Germany (I) C Quench tower Convection heat exchanger (by-passing quench tower) C C EAF Radiation heat exchanger in exhaust gas duct Exhaust gas filtration system ORC

18 EAF Heat Recovery Elbe-Stahlwerke Feralpi Riesa, Germany (II) Thermal user: tire plant Steam and condensate return pipeline Steel Shop ORC Unit Evaporative Cooling System

19 EAF Heat Recovery Elbe-Stahlwerke Feralpi Riesa, Germany (III) 19 dicembre 2013

20 85 t EAF Heat Recovery at Electric Arc Furnace ORI Martin, Brescia, Italy (I) 1,9 MW power

21 Heat Recovery at Electric Arc Furnace ORI Martin, Brescia, Italy (II) Consteel EAF (85t) with evaporative cooling & steam production (Tenova) Start-up: expected in October 2015 ORI MARTIN Steel Work Municipal DH - Summer case: All steam conveyed to ORC - Winter case: Most steam used for district heating Steam at ORC inlet: ~ 16 t/h of steam at 15 bar g- 200 C ORC gross power: ~ 1.9 MWe The ORC operates with a steam flow rate between 2 and 16 t/h, automatically adapting to the EAF melting cycle.

22 Heat Recovery at Aluminum Foundry Melting Furnace, (undisclosed customer) Heat source: Melting Furnace Exhaust gas ORC working fluid: Siloxane Furnace Fuel: Natural gas Start-up: July 2015 ORC electric power: 1.7 MW Heat carrier : Thermal 250 C

23 Heat recovery at iron foundry cupola furnace Fonderia di Torbole Heat source: Exhaust gas ORC working fluid: Siloxane Furnace Fuel: Coke Start-up: first quarter 2016 ORC electric power: 700 kw Heat carrier : Thermal oil Plant type: cupola furnace

24 Turboden at a Glance Thank you for your attention Alessandro Foresti alessandro.foresti@turboden.it Daniele Archetti daniele.archetti@turboden.it 23