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

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Cycle and Industrial Heat Pumps for Waste

1 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 Technologies Organic Rankine Cycle and Industrial Heat Pumps for Waste Heat Upgrading 13 rd -14 th September 2012, Kortrijk Belgium

2 Agenda Company introduction / What we do Introduction to HREII DEMO project Some reference cases 2

Company Introduction Turboden is a leading European company in development and production of ORC (Organic Rankine Cycle) turbogenerators.

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.

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

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 5

6 ORC based heat recovery plants: potential fields of application Typical limits GAS >200 C LIQUID > 100 C VAPOUR > 100 C Cement Glass Oil & Gas Chemicals Steel / Non Ferrous Pulp & Paper Food Waste treatment Thermal Oxidizers Power generation Some reference projects>>> 6

7 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 :

power MW HREII Demo project: first EU estimates 700 600 500 400 300 Total: 629,5 200 Steel: 376,6 100 0 Cement: 145,8 Sectors Glass: 107,1 Power to recovery in Europe (first estimation): 630

8 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.

Steel (EAF) : Riesa ESF Feralpi project Project: Feralpi Germany Reference Case study: Electric Arc Furnace waste heat recovery Heat source: exhaust gas at 1.

9 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

Cement: Ait Baha - Italcementi Project Reference Case

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

power: ~ 2 MWe Client: CIMAR ITALCEMENTI GROUP

10 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 10

Cement: Alesd Holcim Romania Project Project Holcim Romania Reference Case study:

000 ton/day Heat source: exhaust gas @ 360 C (PRS) and hot air @ 250 C (CC)

power: ~ 4 MWe Client: Holcim Romania Holcim Group (Romania) Unit in operation

11 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 11

600 ton/day Heat source: exhaust gas @ 360 C (PRS) and hot air @ 310 C (CC) Thermal oil heat recovery

12 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

$Refractory material: Radenthein RHI project Project RHI Austria Reference Case study: Refractory ovens exhaust gas heat recovery Refractory production capacity: 250 ton/day Heat source:$

13 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

Glass: Cuneo AGC project Project AGC Italy Reference Case study:

production capacity: 600 ton/day Heat source: exhaust gas at

power: ~ 1,3 MWe Final Client: AGC Glass Europe Cuneo Plant

14 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 % 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

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

16 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% 16

Waste gasification: Ankara Turkey project Project ITC Turkey Reference Case study: waste refusal gasification waste heat recovery Heat source: exhaust gas from syngas burning @

17 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

18 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 18

19 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 19

20 Thank you for your attention! For more information: Riccardo Vescovo Sales Manager Heat Recovery 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

ORC technology for low and high temperature

Jahrestagung des ORC-Fachverbandes e.v. 24 th September 2012, Bayreuth ORC technology for low and high temperature Agenda Company introduction / What we do Geothermal Industrial Heat Recovery Some reference