Turn waste heat into value: the dependable Turboden ORC solutions

Transcription

1 Turn waste heat into value: the dependable Turboden ORC solutions Global Cement Waste Heat Recovery Conference and Exhibition Codice doc. 12-A-347-rev.0 City of London - Thursday 14 th - Friday 15 th June 2012

2 Agenda Company introduction ORC based heat recovery plants: main features Some reference cases in cement Other heat recovery fields HREII DEMO: an introduction Turboden / PWPS deployment Conclusion 2

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 Eng. Mario Gaia, former Professor of Energy at the Polytechnic of Milan, 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 Fortune 50 corporation 16th largest US manufacturer $54.3B in 2010 sales 195 countries 210,000 employees United Technologies Corporation UTC Power UTC Hamilton Carrier Research Sikorsky Otis Fire & Security Sundstrand Center EPC Service Large Engines After market Marine Mobile Power Wind Power ORC Technology 4

5 What We Do Biomass Geothermal electricity Solar heat 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 5

6 ORC based heat recovery plants The Thermodynamic Principle of ORC Cycle The turbogenerator uses the hot temperature thermal oil to pre-heat and vaporize a suitable organic working fluid in the evaporator (8 3 4). The organic fluid vapor powers the turbine (4 5), which is directly coupled to the electric generator through an elastic coupling. The exhaust vapor flows through the regenerator (5 9) where it heats the organic liquid (2 8). The vapor is then condensed in the condenser (cooled by the water flow) (9 6 1). The organic fluid liquid is finally pumped (1 2) to the regenerator and then to the evaporator, thus completing the sequence of operations in the closed-loop circuit. 6

7 ORC based heat recovery plants: Integration scheme to Cement Plant 7

8 ORC based heat recovery plants: Main advantages Presence of an intermediate loop (thermal oil or pressurised water) ease of control and operation, even when big fluctuations in primary heat sources great layout flexibility automated and unmanned systems High molecular weight of organic working fluid low enthalpy drop across the turbine low turbine peripheral speed (low mechanical stress and no reduction gear) reduced number of turbine stages high mass flow turbine efficiency > 80 %, good part load efficiencies No corrosion attitudes of working fluids long life of the system and low maintenance requirements Zero Water consumption configuration (option) no water management activities (ph and salts control, water refilling) no water needed low operation requirements, no water depletion 8

9 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 IV quarter

10 Heat Recovery In Cement Production Process Romania Project Holcim Romania Reference Case study: PRS and CC gas waste heat recovery 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: ca. 4 MWe Client: Holcim Romania Holcim Group (Romania) Under Construction; start up expected in June 2012 ORC plant PH boiler AQCboiler 10

11 Heat Recovery In Cement Production Process 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: ca. 5 MWe Client: Holcim Slovakia Holcim Group (Slovakia) Under Construction; start up expected in II quarter

12 ORC based heat recovery plants: A first sight to economics Total WHRS cost Influenced by many specific project related factors: size, ambient temperature, exhaust gas temperatures and flows, number of heat source, layout, electric connection, water availability, etc. Total installed cost of 3,000 /kwnet +/-30% can be used as ball park figure Financial results are driven by few main factors WHRS cost Electricity value may range between 0,13 /kwh (e.g. in Italy with White certificates) to less than 0,05 Operating hrs: the grater, the better (typical values are 7,500 hrs/annum) O&M cost: for ORC based plant it s in the range of 1 % of Capex/year (indicatively half of steam based plant) Some examples: Scenario Best Medium Worst Capex [ /kw] Opex [ /kw/y] Operating hrs Energy value [ /kwh] 0,12 0,08 0,06 WACC 7% 10% 13% PBT 3,2 8,7 > 15 yrs 20 year 36% 15% 6% 12

13 H-REII DEMO Project GOALs: a) To realize an integrated fumes depuration and heat recovery system b) To develop policy and governance actions for reducing CO 2 emissions by valorisation of process effluents in Energy Intensive Industries For more information:

14 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 14

15 Heat recovery from Electric Arc Furnace PROJECT IN A GERMAN IRON&STEEL FACTORY Exhaust gas from EAF (100 t) with steam production Primary heat source: exhaust gas from EAF Steam production: The steam is produced from two different heat sources: 1. Pipe to pipe duct, modified to work with pressurized water at the boiling point 2. Substitution of the quenching tower with a shell and tubes heat exchanger which produces steam. Steam produced: ~ 30 t/h of steam at 27 bar C Steam available for the ORC unit: ~ 20 t/h of steam at 27 bar and 245 C (10 t/h is delivered to an industrial process) Gross power output ORC unit: ~ 3 Mwe High flexibility of the heat recovery system: the ORC properly operates with a steam flow rate between 2 and 22 t/h, automatically adapting its operation to the different operating conditions THE SYSTEM AUTOMATICALLY FOLLOWS THE EAF MELTING CYCLE 15

16 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.

17 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

18 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

19 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% 19

20 20

21 Turboden strong points R&D Sales/marketing Design Operations & manufacturing Aftermarket service Participation in national & EU research programs Cooperation with EU Universities and Research Centres Thermodynamic cycle optimization Working fluid selection & testing Thermo-fluid-dynamic design and validation Implementation & testing of control/ supervision software Pre-feasibility studies: evaluation of technical & economical feasibility of ORC power plants Customized proposals to maximize economic & environmental targets Complete in-house mechanical design Proprietary design and own manufacturing of ORC optimized turbine Tools - Thermo-fluiddynamic programs - FEA - 3D CAD-CAM - Vibration analysis Outsourced components from highly qualified suppliers Quality assurance & project management In house skid mounting to minimize site activities Start-up and commissioning Maintenance, technical assistance to operation and spare parts service Remote monitoring & optimization of plant operation Many patents obtained 21

22 Turboden facts & figures (Last update: February 2012) 22

23 Conclusions Turboden & PWPS ORC based WHRS for cement Ease of integration into existing plants Very low O&M costs Automatic and unmanned operations Profitable plants Optimum solution for industrial users minimising any effect on primary process Turboden & PWPS Have real experience in WHRS in Energy Intensive Industries (Cement, Steel, Glass) Can provide customised solutions to meet customers requests Have established a network with major stakeholders (WHR exchangers makers, WHR plant integrators, financing companies and record access to European funds) The dependable technological partner to successfully exploit WHR 23

24 Thank you 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