ORC for Heat Recovery in Energy Intensive Industries: the H-REII DEMO project Marco Baresi Turboden Institutional Relations Manager

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EEIP BIENNIAL CONGRESS Energy Recovery in Industry: Opportunity for energy efficiency, 24-25 October 2012, Berlin ORC for

1 EEIP BIENNIAL CONGRESS Energy Recovery in Industry: Opportunity for energy efficiency, October 2012, Berlin ORC for Heat Recovery in Energy Intensive Industries: the H-REII DEMO project Marco Baresi Turboden Institutional Relations Manager

2 Fortune 48 th largest US corporation 16 th largest US manufacturer United Technologies Corporation $58.2B in 2011 sales Business in 180 countries 200,000 employees UTC Power UTC Fire & Security Hamilton Sundstrand Carrier Research Center Sikorsky Otis EPC Service Large Engines After market Marine Mobile Power Wind Power ORC Technology 2

3 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 600 kw to 6 MW customized solutions up to 15 MW 3

4 4

5 H-REII ( ) HREII DEMO ( )

The HREII project: potential in Italy 1000 900

Glass Non ferrous* Cement Steel Gas Comp.

recovery at 8000h/yr Power to recover in the 4

6 The HREII project: potential in Italy GWh/yr Flat Glass Non ferrous* Cement Steel Gas Comp. Station* Energy recovery at 5000h/yr Energy recovery at 8000h/yr Power to recover in the 4 investigated sectors: ~ 253 Mwe from GWh/y to GWh/y ~ 8% of the savings target for the Italian industrial sector in 2016 Source: Italian PAEE 2011

cogeneration Example of intervention: use of heat recovery to produce electricity!

7 Italian incentive since 2011 Authority for electricity and gas resolution EEN 9/11 28 th October 2011 Industrial processes: generation of electricity from renewable sources, recovery or cogeneration Example of intervention: use of heat recovery to produce electricity! White Certificate Before (general) White Certificate November 2011 (specific for heat recovery) 19 /MWh 60 /MWh Is it enough to start?

incinerator Customer : MIROM (Roeselare-Belgium) In operation since: II quarter 2008 Heat source: hot water at 180

8 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% 8

$Heat Recovery In Refractory Production Process$ $heat recovery Refractory production capacity: 250$ down to ca. 150 C ORC electric power: ca.

9 Heat Recovery In Refractory Production Process 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 ORC electric power: ca. 1 MWe Client: RHI GROUP (Radenthein - Austria) In operation since I quarter

gas at approximately 500 C ORC electric power: ca.

10 Heat Recovery In Glass Production Process Reference Case study: Float glass production process Glass production capacity: 600 ton/day Heat source: exhaust gas at approximately 500 C ORC electric power: ca. 1,3 MWe Final Client: AGC Glass Europe Cuneo Plant General contractor: GEA Bischoff In operation since I quarter

Heat Recovery In Cement Production Process Reference

down to 220 C (extra heat used for raw material pre

11 Heat Recovery In Cement Production Process 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) ORC electric power: ca. 2 MWe Client: CIMAR ITALCEMENTI GROUP (Morocco) In operation since

12 Heat Recovery In Cement Production Process 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) ORC plant Thermal oil (PRS) and pressurised water (CC) heat recovery loops ORC electric power: ca. 4 MWe Client: Holcim Romania Holcim Group (Romania) In operation since 2012 EEIP BIENNIAL PH CONGRESS for energy efficiency, October 2012, Berlin12 boiler Energy Recovery in Industry: Opportunity AQCboiler

13 Heat Recovery from Gas Turbine Reference Case Study: Heat recovery from Solar CENTAUR gas turbine in a Gas Compressor station in Canada Gas Turbine prime power: 3.5 MWe Gas Turbine efficiency: 28% ORC electric power: 1 MWe General Contractor: IST (Innovative Steam Technologies) Final Client: TransGas In operation since IV quarter

14 Heat Recovery from Internal Combustion Engines: 12 reference projects Project ORC Module Site Engines Pisticci I Oxon FinPower Pisticci II Cereal Docks Eukrasia Ulm Kempen Mondopower HSY GazProm2 TURBODEN 18 HR SPLIT (1,8 MWe) In operation since IV quarter 2010 TURBODEN 6 HR SPLIT (0,6 MWe) In operation since IV quarter 2008 TURBODEN 6 HR DIR. EXCH. (0,6 MWe) In operation since II quarter 2009 TURBODEN 40 HR SPLIT (3,8 MWe) In operation since II quarter 2012 TURBODEN 6 HR DIR. EXCH. (0,6 MWe) In operation since I quarter 2012 TURBODEN 6 HR SPLIT (0,6 MWe) In operation since II quarter 2010 TURBODEN 10 HR cogenerative(1 MWe) Under construction TURBODEN 6 HR cogenerative (0,6 MWe) In operation since I quarter 2012 TURBODEN 10 HR (1 MWe) Under construction TURBODEN 14 HR (1,3 MWe) In operation since III quarter 2011 TURBODEN 10 HR SPLIT (0,987 MWe) Under construction Pisticci (IT) Pavia (IT) Visano (IT) Pisticci (IT) Portogruaro (IT) Catania (IT) Senden(DE) Kempen (DE) Chivasso (IT) Ämmässuo(FIN) Moscowregion(RU) 3 x 8 MWe Wartsila Diesel engines 1 x 8 MWeMAN Diesel engine 1 x 7 MWe Wartsila Diesel engine 2 x 17 MWe Wartsila Diesel engines 1 x 7 MWe Wartsila Diesel engine 2 x 1 MWeJGS/GE gas engines+ 3 x 0,8 MWeJGS/GE gas engines + 1 x 0,6 MWeJGS/GE gas engine 2 x2 JGS/GE gas engines (+ additional heat from the process) Gas engines 1 x 17 MWe Wartsila Diesel engine 4 x 4 MWeMWM gas engines 5 x 2 MWeMTU engines Fater TURBODEN 7 HR DIR. EXCH.(0,7 MWe) Under construction Pescara (IT) 1 x 8 MWe Wartsila Diesel engine 14

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

15 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

H-REII DEMO Project The main goals: a) to realize an integrated fumes depuration and heat recovery system in Iron & Steel Industry (EAF - Electric Arc Furnace) b) to

16 H-REII DEMO Project The main goals: a) to realize an integrated fumes depuration and heat recovery system in Iron & Steel Industry (EAF - Electric Arc Furnace) b) to develop policy and governance actions for reducing CO 2 emissions by valorisation of process effluents in Energy Intensive Industries For further information:

available for the ORC Unit steam produced: ~ 30 t/h of steam at 27 bar -

17 Heat recovery from Electric Arc Furnace PILOT PROJECT GERMAN IRON & STEEL FACTORY Exhaust gas from EAF (100 t) with steam production ~ 20 t/h available for the ORC Unit steam produced: ~ 30 t/h of steam at 27 bar C ~ 10 t/h delivered to an industrial process Gross power output ORC unit: ~ 3 MWe 17

18 Heat recovery from Electric Arc Furnace 25% 30% of the power inserted in the furnace is lost in the exhaust C C C 70% of the lost power could be recovered ORC Target: 3-5% of the EAF installed power 18

19 HREII DEMO project: first EU estimates MWh/yr Flat Glass * partial estimtes Non ferrous* Cement Steel Gas Comp. Station* Energy recovery at 5000h/yr Energy recovery at 8000h/yr Power to recover in the 5 investigated sectors: 2.59 GWe from 13,3 TWh/y to 21,3 TWh/y (*)

20 Heat Recovery: a cluster of different actors in white economy Opportunity for Industrial policy more sustainable industrial processes targets industrial investments Opportunity for Innovation policy technology development - R&D 20

21 Thank you for the attention Marco Baresi, Turboden Institutional Relations Manager

ORC for Waste Heat Recovery in Industrial Processes: the HREII Demo Project

ORC for Waste Heat Recovery in Industrial Processes: the HREII Demo Project Turn waste heat into value: the dependable Turboden ORC solutions International Symposium on Advanced Waste Heat Valorisation