Termotecnica Pompe di Industriale. Gli atti dei convegni e più di contenuti su

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1 Termotecnica Pompe di Industriale Calore Gli atti dei convegni e più di contenuti su

2 Doc. 16-COM.P-4-rev.0 Update:

3 INDEX STEAM & POWER ORC A Look to the Product COMPANY OVERVIEW Turboden & Bono Sistemi STEAM & POWER ORC STEAM & POWER Manufacturing Processes Cogeneration TECHNOLOGIES BENCHMARK

4 STEAM & POWER ORC A look to the Product What it is Steam & Power (ST&P) ORC is a new technological solution for Combined Heat & Power (CHP) generation. The Innovation Principle Steam & Power (ST&P) ORC allows cogeneration of electricity and medium pressure steam, using natural gas as fuel, with a very high overall energy efficiency. The innovation principle of Steam & Power ORC is the temperature level of the ORC cycle.

5 STEAM & POWER ORC A look to the Product The Technology Steam & Power ORC comes from the technological coupling of the Turboden pioneering ORC solution and Bono Sistemi experience in high temperature gas fired boiler manufacturing. MANUFACTURING PROCESS ST&P ORC HTH BOILER ST&P Focus ST&P ORC is a new type of CHP system, using a conventional fuel to generate electricity and steam, directly exploitable in manufacturing processes.

6 COMPANY OVERVIEW About Turboden

7 COMPANY OVERVIEW About Turboden Turboden ORC Expertise Turboden is an Italian company and a global leader in the design, manufacture, and aftersales services of Organic Rankine Cycle (ORC) turbogenerators since Turboden and MHI Since 2013 Turboden is part of Mitsubishi Heavy Industries, one of the world's leading heavy machinery manufacturers, with consolidated sales of over $33 billion (in fiscal 2014). Turboden at a Glance more than 320 plants in 33 countries 270 ORC units in operation

8 COMPANY OVERVIEW Turboden ORC System The Traditional Solutions CHP & HR Turboden ORC technology is used for cogeneration (CHP) or power only generation from renewable sources or heat recovery. The range size Turboden ORC solutions range from 200 kw to 20 MW electric per single turbine. BIOMASS GEOTHERMAL HEAT RECOVERY OIL & GAS WASTE TO ENERGY SOLAR THERMAL POWER The Innovative Solutions ST&P Steam & Power Cogeneration is the most innovative application of Turboden ORC System in combination with BONO High Temperature Heaters (HTH).

9 COMPANY OVERVIEW About Bono

10 COMPANY OVERVIEW About Bono Bono Expertise Industrial Boiler Since 1958 Bono is dedicated to design, manufacture, install and service industrial boilers for standard and special applications. Bono at a Glance Headquartered in Italy, Bono is part of the Cannon Group, an international engineering company active worldwide with more than 18 locations and a wide service network supporting customers locally. Bono Design Guideline The Bono focus is to develop the best technologies in energy saving, emissions reduction and smart solutions for customers. These green and efficient solutions were selected by several EPC contractors making BONO one of the recognized leaders in this field.

11 COMPANY OVERVIEW BONO HTH System Application Traditionally BONO HTH, an innovative and proprietary design of Thermal Oil Heater, finds application in those industrial fields where high and precise process temperatures are required, such as production of syntetic fibers, chemical processes, wood industry, oil stocking and transportation and indirect steam generation. From the O&G to companies operating in food & beverage, pharmaceutical, paper and many other energy consuming industries. The Technology - Boiler Thermal fluid horizontal type heaters with multi-tubular design, built for capacities ranging up to 40 MW. The Technology High Temperature Thermal fluid syntethic type, can be used both in liquid and in vapour phase up to 400 C.

12 STEAM & POWER ORC How it works Steam Production Heat Source The fuel (natural gas, syngas, diesel, fuel oil, wood pellet and others) is fed to the combustion chamber of Bono Sistemi boiler. There it is mixed with preheated air and burned. Thermail Oil The combustion heat is transferred to the thermal oil loop. Electric Power The hot thermal oil makes the ORC working fluid evaporating. The organic vapour generated expands to the turbine that drives an electric generator, producing electric power. Downstream the turbine, the organic vapour pre-heats the organic liquid in the regenerator and is then condensed at high temperature releasing its latent heat for steam generation, to feed the manufacturing process.

13 STEAM & POWER ORC Features Steam & Power ORC advantages Fuel flexibility (for both gaseous and liquid fuels) High total efficiency Prevailing steam output High availability High flexibility to partial load operation down to 20% Low operation & maintenance cost Modularity Outdoor installation Island operation Combined with other CHP technologies if required

14 STEAM & POWER ORC The Sizes CHP Alternative to Traditional Steam Boiler Steam & Power ORC could be used to substitute old steam generators or to be placed in parallel to existing steam generating system in a sustainable and cogenerative way. ST&P MAIN SIZES * Steam capacity [ton/h] Electrical gross output [kw] Electrical gross efficiency [%] ** Captive consumption [%]*** Natural gas consumption [Sm3/h] TD 4 ST&P TD 6 ST&P TD 10 ST&P TD 15 ST&P TD 25 ST&P ,300 1,910 3, ,300 2,170 *Intermediate sizes avalible upon request. Expected performances with 12 bara steam output; ** Respect to fuel input; *** On electrical output gross.

15 Electrical efficiency [%] STEAM & POWER ORC Performance Features 20 Steam Pressure vs. Electrical Efficiency Steam output pressure [bara] Efficiency depending on steam pressure ST&P electrical performances vary with steam output pressure. ST&P can be operated between 6 bar and 30 bar of steam output.

16 STEAM & POWER ORC A Case Study Feasibility ST&P TYPE TD 15 Steam capacity [ton/h] 15 Electrical gross output [kw] 1,910 Electrical gross efficiency [%] * 15 Captive consumption [%] ** 7 CAPEX [ /kwe]*** 1,800 Maintenance cost [ /kwhe] scenario Italy Electricity price [ /MWh] 135 PBT [years] 2.5 IRR [%] 40 % 2 scenario - World Electricity price [ /MWh] 110 PBT [years] 4,0 IRR [%] 25 % HYPOTHSIS and NOTES 1. Differential analysis of CHP technology compared to a conventional steam generation system (only thermal) 2. Existing boiler efficiency 90% 3. Steam 12 bara 4. Natural gas price 30 /MWh 5. Equivalent working hours 7,400 h/year 6. Italian scenario considering Italian incentives regualtion for CAR (white certificates, electricity taxes regualtion and natural gas defiscalization) * Respect to fuel input ** On electrical output gross *** Excluding civils and electrical connection

17 STEAM & POWER Manufacturing Processes Cogeneration STEAM & POWER

18 STEAM & POWER The Cogeneration

19 TECHNOLOGIES BENCHMARK The Cogeneration Advantages Excellent economic return of investment (PBT < 3 years, IRR > 30%) Hedge against rising electricity costs Efficient & sustainable solution for increasing steam demands CHP during grid outages - Island Mode Avoided costs of new regulations Environmental Benefits Becoming greener Reduced GHGs emissions Increased energy output per unit of fuel consumption Suited for sustainability plans

20 STEAM & POWER Manufacturing Processes Cogeneration At Your Service Steam & Power ORC was conceived to satisfy many manufacturing processes requiring electricity and relevant amount of medium pressure steam. More Energy No Losses Effective CHP systems satisfy directly the thermal requirement of the manufacturing process. ST&P ORC does producing thermal energy in the form of steam and minimizing losses. Just Steam & Power ST&P ORC produces electricity & steam without hot water to be exploited.

21 STEAM & POWER Manufacturing Processes Best Application

22 STEAM & POWER A case study feasibility ST&P + IC Engine ST&P TYPE TD 25 IC ENGINE World scenario Steam capacity [ton/h] 25 Electrical gross output [kw] 3,250 Electrical gross efficiency [%] * 15 Steam capacity [ton/h] 1.7 Electrical gross output [kw] 4,401 Electrical gross efficiency [%] * 46 Electricity price [ /MWh] 110 PBT [years] 2,8 IRR [%] 37 % Captive consumption [%] ** 7 Captive consumption [%] ** 3,5 CAPEX [ /kwe]*** 1,500 CAPEX [ /kwe]*** 620 Maintenance cost [ /kwhe] Maintenance cost [ /kwhe] HYPOTHSIS and NOTES 1. Differential analysis of CHP technology compared to a conventional steam generation system (only thermal) 2. Existing boiler efficiency 90% 3. Steam 12 bara 4. Natural gas price 30 /MWh 5. Equivalent working hours 7,400 h/year * Respect to fuel input ** On electrical output gross *** Excluding civils and electrical connection

23 TECHNOLOGIES BENCHMARK - Overview CHP PLANT RECIPROCATING ENGINE ELECTRICITY GAS TURBINE FUEL STEAM TURBINE STEAM & POWER ORC STEAM LOSSES

24 TECHNOLOGIES BENCHMARK Market Availability Map Advantages ST&P covers a frame of electrical output that is unmet by competing CHP technologies, suitable for medium pressure steam generation (i.e. steam turbines and gas turbines) ST&P from 500 kw to 3 MW per single unit

25 TECHNOLOGIES BENCHMARK - Performance

26 TECHNOLOGIES BENCHMARK Features Reciprocating Engine Gas Turbine ST&P ORC Steam Turbine CAPEX Low Medium High High Electrical output High High Medium Low Steam output Low Medium High High Total efficiency Low Medium High High Market availability & Modularity Flexible partial loads High Low High Low Medium Low High Low Availability Low Medium High Medium

27 THANK YOU FOR YOUR ATTENTION!

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