Waste Heat Recovery using Organic Rankine Cycle turbines

Transcription

1 Nicolas Bernier, 5ft June 2018 Waste Heat Recover using Organic Rankine Ccle turbines

2 Industrial waste heat : the example of France (1) Heat balance, fuel furnace, permanent regime Fumes loss 25 to 60 % Loss due to openings 3 to 10 % Fuel 100 % Useful heat 100 % Loss due to walls 3 to 10 % Loss due to conveors 3 to 10 % dring Source : ADEME (2014)

3 Industrial waste heat : the example of France (2) Tpicall : steel mill, cement & glass factories Diffuse discharge Gaseous discharge Liquid discharge Tpicall : agro, paper, chemical industr dring Source : ADEME (2014)

4 Industrial waste heat : the example of France (3) Useful heat for production Fuel consumption Waste heat definitel lost Recoverable Waste heat Waste heat recovered and exported waste heat Waste heat recovered on site - Heating networks - Electricit production Energ efficienc actions on site Waste heat avoided dring Source : ADEME (2014)

5 Industrial waste heat : the example of France (4) Figures in brief 319 TWh : 275 TWh (industr) 44 TWh (refineries) process : furnaces, others paper cardboard refineries steel and other metals chemistr plastics drer, boilers temperature > 100 C fumes, vaporized fluids agro-industr 3x8h with weekend stops Losses from biolers fumes Industrial waste heat >100 C 51 TWh Remaining heat from drers Losses from furnaces fumes 3x8h no weekend stops Industrial waste heat >100 C 51 TWh dring Source : ADEME (2014) non metal materials

6 Industrial waste heat : the example of France (5) 1,1 TWh 250 sites 1,400 MWe potential Fuel consumption Waste heat Gross power production Net power production dring Source : ADEME (2014)

7 Industrial Waste Heat Recover Purchased fuels (oil, gas, biomass, etc.) Genset ST, ORC Heat generation (boilers, fired heaters/furnaces, etc.) Electricit generated (engine, ST, ORC, etc.) Electricit purchased Process (oil, gas, biomass, etc.) ORC Electricit Cooling sstem (cooling towers, closed loop cooling, etc.) Heat Cold Surroundings (rivers, air, etc.)

8 Organic Rankine Ccle Expanding heat to power scope of possibilities no fuel no combustion no emissions no chemicals* no need for high pressure suitable with temperatures as low as 80 C * hot loop

9 WHR using ORC technolog in the world In operations for 35 ears, producing more than 3,000 MW worldwide! Source : orc-world-map.org (2015) More plaers since the ears 2000

10 WHR using ORC technolog : tpes of activities Source : orc-world-map.org (2015)

11 Reminder of Organic Rankine Ccle (ORC) technolog Generator ORC Turbine Waste heat Cooling Working fluid vaporized (vapor phase) Heat exchanger - thermal oil - superheated water - (hot gas) Organic Fluid Loop Condenser Hot loop Evaporator Dr coolers Cold Loop - water Working fluid condensed (liquid phase) Pump Wet coolers

12 Figures for a ver low enthalp waste heat recover

13 Comparative table between ST and ORC solutions (1) Steam turbines ORC turbines fluid purified water steam thermal oil or superheated water pressure 20 to 300 bar 5-20 bar temperature C C chemicals es (water purification) no reheating device es (water purification) no dr purified water steam (HP) «organic» fluid Hot loop Working fluid loop fluid possible droplets at LP stages water consumption es no pressure inlet turbine 20 to 300 bar 5-20 bar temperature inlet turbine C C pressure oulet turbine temperature outlet turbines CHP < 2 bar C possible ~60 C possible Turbine blades up to tens of stages 1 to ~15 diameter up to several meters 10 to 60 cm rotation speed rpm up to 1800 rpm

14 Comparative table between ST and ORC solutions (2) ORC versus steam turbines technologies Financial benefits choosing ORC tech. ST ORC CAPEX + - Installation and commissioning - + Low Exploitation, availabilit (incomes) - + Yes No Maintenance, OPEX - + Lifetime Value and options at the end of the PPA - + Water consumption, chemicals Yes No High Low Overall benefits at the end of the PPA - + ST ORC Availabilit 80-90% 98% Load variation -5/+5% -60/+120 High Corrosion (efficienc decrease) Pressure, temperature Maintenance, OPEX

15 Steam and ORC turbines Steam turbine ORC turbine LP stages HP stages Turbo expander: combination of a micro turbine with an integrated generator Potential applications are not onl ORC but also C02 ccle, natural gas expansion, process gas expansion, hot air energ recover

16 Various ORC applications Biogas, landfill gas Solar Biomass Geothermal Enhancement of biogas engine via exhaust, water jacket or both Direct biogas to electricit conversion with boiler Solar CHP with CSP field Solar CHP with CSP and heat storage Biomass to electricit Biomass CHP Isolated site Natural hot sources Medium temperature wells (from 80 C) Industrial Waste Heat Recover Process Heat Exhaust gases Waste steam Renewable Energies Diesel and gas gensets Efficienc enhancement via exhaust, water jacket or both Energ Efficienc Transportation Vessels Railroad Heav Dut Trucks Education and research With boiler simulating heat source

17 Industrial waste heat recover fumes industrial process excess steam cement factories still mills foundries glass furnaces refineries aluminium smelters incinerators plants treating sewage through incineration paper factories agro-industr etc.

18 Case stud : cement factor (1)

19 Case stud : cement factor (2) Scope / Investment Performance 2x ATM-3000H (2 x ORC 3000 kwe) Estimated CAPEX for turnke PP : Incentives : Annual OPEX : 20 MUSD MUSD Net production : ORC availabilit : Global availabilit : Annual production : 5742 kwe 8500 h (97 %) 8000 h (91%) GWh Profitabilit TRI (80 USD/MWh): TRI (100 USD/MWh): LCOE (10 ears) : LCOE (20 ears) : ears 5 ears 54 USD/MWh 32 USD/MWh Electricit tariff of 80 USD/MWh

20 Case stud : WHR from biomass drer (1) Charcoal and pelets factor: recovering excess heat from the drer 200 kw Electricit Production Heat exchanger 2,5 MW recovered thermal power Turbine 130 C Hot water loop 30 kg/s 50 C Evaporator Condenser 110 C Cold water 19 kg/s Pump 30 C ORC (Scope of the pre-quotation) 200 C Hot air

21 Case stud : WHR from biomass drer (1) Scope / Investment Performance 1x ENO-200LT (ORC 200 kwe) Net production : ORC availabilit : Global availabilit : Annual production : Estimated global CAPEX : Incentives : Annual OPEX : 600 kusd 0 15 kusd 180 kwe 8670 h (99 %) 8500 h (97%) 1,530 MWh Profitabilit TRI (100 USD/MWh): LCOE (10 ears) : 2,500 2, ears 92,5 USD/MWh 1,500 1, ,000 Electricit tariff of 0.1 USD/kWh

22 Internal Combustion Engines (ICE) heat recover Diesel, HFO, gas, biogas Exhaust gases and possibl jacket water heat the thermal oil with a heat exchanger Approximatel 10% additional electricit is produced

23 Case stud : WHR from a biogas engine With a Jenbacher biogas engine

24 Gas flaring ORC technolog provides a solution to reduce flaring and venting Low qualit gases from well are diverted to a boiler (Thermal Oil Heater).

25 Case stud: oil wells conversion > geothermal (1) The estimated recoverable : - heat output is 1580 kwth - net power output is 88 kwe Electricit Production 98 kwe 88 kwe Ambient temperature : 31 C Hot water 110 C 19 kg/s Turbine 50 C Evaporator 1580 kw th Condenser Pump 90 C ORC (Scope of the pre-quotation) 40 C Cooling sstem

26 Case stud: oil wells conversion > geothermal (2) 800 Scope / Investment 600 ENO-100LT (ORC 100 kwe) Estimated global CAPEX : Incentives : OPEX : kusd 0 30 kusd Performance Gross production : Net production : ORC availabilit : Global availabilit : Annual production : kwe 88 kwe 8670 h (99 %) 8500 h (97%) 748 MWh Electricit tariff of 0.1 USD/kWh 2,500 2,000 1,500 Profitabilit 1, TRI (100 USD/MWh): TRI (200 USD/MWh): LCOE (10 ears) : LCOE (20 ears) : 6+ ears 3- ears 87 USD/MWh 63,5 USD/MWh Electricit tariff of 0.2 USD/kWh 18 20

27 Case stud: oil wells conversion geothermal (3) Estimate of electricit production for various flow rates and temperatures of the source Electricit production kw Ambient temperature : 31 C Mass flow rate kg/s

28 Ship s diesel engine heat recover (1)

29 Ship s diesel engine heat recover (2)

30 Ocean Thermal Energ Conversion (OTEC)

31 Contact details Thank ou for our attention! Nicolas Bernier