Presentation of the GMK ECOCAL ORC-power plant located in Hennstedt / Germany. Power from Biomass. Case Study

Transcription

1 Presentation of the GMK ECOCAL ORC-power plant located in Hennstedt / Germany Power from Biomass Case Study

2 Content I Content 1 The Organic Rankine Cycle General description ECOCAL ORC-power plants The company GMK The ECOCAL ORC power plant Hennstedt The Power Plant The ORC-Module The Heat Supply... 8

3 Chapter 1 The ORC - Organic Rankine Cycle The Organic Rankine Cycle 1.1 General description The ORC process (Organic-Rankine-Cycle) is a thermodynamic process, where instead of water a low boiling, organic substance circulates as working medium. This can occur at temperatures from 100 C (212 F) on and pressures far under 20 bar to extract a maximum work from the organic rankine cycle-process. With organic rankine cycle-power plants it is possible, to also turn small sources of thermal energy efficiently into electrical energy. This can simply be achieved with an organic rankine cycle-module mounted on a base frame. Due to the thermodynamic properties of the synthetic working medium it is possible to generate power compared to nonorganic rankine cycle-power plants from waste heat, geothermal sources, combustion of biomass or solar thermal sources. On the picture below a schematic of the ORC can be seen. Thermal energy in form of hot thermal oil, hot flue gases or geothermal water is supplied. An organic working medium starts to boil in the evaporator thus creating a pressure and entering a turbine. There the potential energy stored in the pressurized and hot working medium is turned into mechanical and electrical energy. After leaving the turbine the superheated working fluid passes its energy to the recuperator and flows into the condenser where it is liquefied and drawn by the feed pump to close the cycle. Picture 1: Schematic of the Organic Rankine Cycle

4 Chapter 1 The ORC - Organic Rankine Cycle ECOCAL ORC-power plants ECOCAL stands for "ecological caloric" and describes our organic rankine cycle product line for the electrification of biomass like wood chips, agricultural waste wood and such from the industry. It is the system based on the organic rankine cyle process for a combined heat and power production being capable to cover a range of heat and power devices from an electrical power output of 0.3 MWel on, more efficient and much more economic than the ordinary water steam process (CRC-process). In comparison of ECOCAL -organic rankine cycle -technology with the water steam power process ECOCAL offers significant advances compared to power plants operating based on the ordinary water steam cycle. For almost a hundred years it has been possible to produce heat and electricity by the combustion of piece wood with the help of steam engines. Such plants are mainly composed of: a firing for solid fuels, a steam boiler for the production of water steam, a machine such as a steam motor or a steam turbine coupled with a generator, and heat or air condensers. Next to steam powered machines the boiler is the most expensive main component in the branch of steam power device production. Such systems for the production of high pressurized steam are very complex and sumptuous to produce. For the fabrication of steam boilers, steam pipes and steam boiler armatures, very durable, corrosion withstanding and ferritic-martensistic steel or high temperature withstanding austenitic power plant steel has to be used. Additionally, these special parts are only allowed to be mounted by qualified steam power plant assembling companies. Contrary to the previous, for the production of electricity in ECOCAL -power plants do not require a steam boiler. Furthermore in organic rankine cycle power plants the maximal pressures amount up to 10 bar. This means that for the production of ECOCAL - modules ordinary low cost boiler steel can be used. Based on those pre named properties, ORC-power plants are much more cost effective to erect. Also because of the low pressures in ECOCAL -power plants they do not have to be supervised by specially trained personnel which leads to a much more economic working of those plants as well.

5 Chapter 1 The ORC - Organic Rankine Cycle Picture 2: Schematic of an ECOCAL Organic Rankine Cycle power plant In the Schematic above a typical ECOCAL power plant is visualized. On the left is the fire box with the thermal oil boiler. The intermediate thermal oil cycle is pumped to the ORCmodule where it passes its energy to the evaporator to start the ORC-process. Next to the produced electricity the produced heat can be fed into heating networks, green houses, drying processes or other heat users.

6 Chapter 2 The company GMK The company GMK GMK is one of the leading ORC-module developers and producers in Europe. GMK offers the lay out, production, set up and services for complete ORC-modules as a one stop supplier. The core competence of GMK is the lay out and engineering of ORC-modules, while the production of the power devices is carried out within the holding. At the location in Bargeshagen, Northern Germany approximately 25 engineers, scientists and industrial workers are employed. In 1994 the company had been founded in the process of a research project which had the objective of testing the energetical use of biomass, in cooperation with the Rostock University. Today GMK belongs to Germania Technologieholding with a share of 100%. GMK s product portfolio covers ECOCAL - power from biomass GEOCAL - power from geothermal heat INDUCAL - power from waste heat

7 Contact 3 The ECOCAL ORC power plant Hennstedt 3.1 The Power Plant Picture 3: 3-D view of the ECOCAL power plant located in Hennstedt In the year 2007 a company founded by farmers build a bio-energy center located in Hennstedt / northern Germany. The complex consists of photo voltaic power, wind power and a biogas and wood chips fired power plant that both together supply the nearby city and greenhouses for the growing of tomatoes with heat. In the following the wood chip power plant with a GMK ORC-unit is described. First woodchips from surrounding agricultural wood are fed into an Austrian made fire box with a stoker grate. After the combustion the hot flue gases enter a thermal oil boiler over a heat bridge, as can be seen in the 3-D scheme above. In the boiler thermal oil is heated up to supply the heat from the firing to the ORC-module. After the flue gases passed through the boiler the rest thermal energy is extracted by the economizer for heating purposes and enter an electrical filter after being cooled down. The Boiler room with the firing and the thermal oil boiler can be seen in the back of the picture 4 and 5 below.

8 Contact Picture 4: Internal view of the ECOCAL power plant boiler room located in Hennstedt Picture 5: Internal view of the ECOCAL power plant boiler located in Hennstedt

9 Contact 3.2 The Hennstedt ORC-Module Picture 6: 3-D schematic of the ECOCAL ORC unit located in Hennstedt The heat produced in the firing of the power plant is turned into electricity in an EC ORC unit produced by GMK. Hot thermal oil enters the machine at a temperature at 590 F and produces 1.5 MW of electricity. After producing electrical energy the heat can still be used for district heat and for the supply of the green houses on a temperature level of 194 F and 158 F. Picture 7: View of the ORC-turbine in Hennstedt

10 Contact Picture 8: View of the ORC-feed pump in Hennstedt 3.3 The Heat Supply After producing electricity with the ORC-unit the heat is supplied to greenhouses and the city of Hennstedt as can be seen in Picture 9. Picture 9: View onto the green houses in Hennstedt

11 Contact Head of Sales: M.Sc. Nico Timm Phone: Internet: