ORC turbogenerators for medium/low temperatures demonstration projects and commercial plants

Transcription

1 Geothermal Energy Exhibition - 1 st Edition 23 rd - 24 th - 25 th of September 2009 ORC turbogenerators for medium/low temperatures demonstration projects and commercial plants Doc. 09Z00990 Carlo Minini Turboden srl

2 Who we are Turboden, European leader in ORC technology for the generation and cogeneration of heat and power from renewable energy and heat recovery. Since 2009 a Pratt & Whitney Power Systems company. Pratt & Whitney, a division of United Technologies Corporation (UTC), is a world leader in the design, manufacture and service of aircraft engines, industrial gas turbines and space propulsion systems. Pratt & Whitney Power Systems (PWPS), the industrial gas turbine business of Pratt & Whitney, provides power generation and mechanical drive solutions for the electric generation, oil and gas markets, including service through the entire product life cycle PWPS also manufactures and markets the PureCycle system that can harness heat in the form of hot water from many different sources such as geothermal or oil & gas co-produced fluids, reciprocating engines, and industrial waste heat to generate clean and reliable electricity. 2

3 What We Offer ORC is a commercial technology for distributed production of combined heat and power from various renewable energy sources Turboden designs and develops turbogenerators based on the Organic Rankine Cycle (ORC), a technology particularly suitable for distributed generation standard size Turbogenerators from 400 kw el to 2.5 MW el customized products up to 7 MW el and scalable for larger plants 3

4 Layout Some Examples TURBODEN 7 Standard CHP units TURBODEN 18 4

5 Turboden - 30 Years Experience 1984: a 40 kw el ORC turbogenerator for a solar application in Perth, Australia 1987: a 3 kw el CHP biomass ORC turbogenerator plant in Milan 2008: a 3 MW el ORC turbogenerator for waste heat in Belgium 5

6 Turboden at a Glance R&D Participation in national & EU research programs Cooperation with EU Universities and Research Customized proposals Centres to maximize economic & environmental targets Thermodynamic cycle optimization Working fluid selection & testing Thermo-fluid-dynamic design and validation Implementation & testing of control/supervision software MARKETING/SALES Evaluation of technical & economical feasibility of ORC power plants Support for applications to Public Authorities for Green Power incentives DESIGN Complete in-house mechanical design Proprietary design and own manufacturing of ORC optimized turbine TOOLS Thermo-fluiddynamic programs FEA - Finite Element Analysis 3D CAD-CAM Vibration analysis OPERATION & MANUFACTURING Outsourced components from highly qualified suppliers Quality assurance & Project management In house skid mounting to minimize site activities SERVICE Start-up and commissioning Maintenance, technical assistance to operation and spare parts service Remote monitoring & optimization of plant operation Many patents obtained 6

7 Turboden experience at a Glance (Last update: May 2009) 7

8 ORC Applications Biomass Heat Recovery Geothermal Turboden/PureCycle ORC s can produce electricity from geothermal resources with medium to low temperature, normally ranging between 90 C and 180 C Thermodynamic Solar 8

9 ORC Applications Geothermal ORC technology is particularly suitable for the exploitation of medium to low enthalpy sources Cost-effective solution with power output over 250 KW el and water temperature above 90 C* * 195 F 9

10 Binary Cycles Geothermal energy exploitation for electricity is heading towards more demanding applications: Low temperature resources Scaling fluids High gas content (to be reinjected) The binary systems answer to these challenging issues In principle binary cycle geothermal power plants are thermodynamically similar to conventional nuclear and fossil plants in that the working fluid undergoes a closed cycle Separated loops imply: Clean working fluid in contact with the turbine components Gases can be reinjected The geothermal fluid is confined and is fully reinjected It keeps the well-head pressure Negligible environmental impact 10

11 Binary Cycles Options for binary cycles exploiting variable temperature heat sources Rankine cycles: Water / Steam Hydrocarbon fluids Non flammable fluids (to be chosen according to the application) Non Rankine cycles: Kalina (Water Ammonia absorption cycle) Facts & Figures 1912 in Larderello, Italy, a 250 kw indirect cycle plant was put into operation * First geothermal binary plant in Kamchatka peninsula in 1967 Today binary plants are the most widely used type of geothermal power plant: more than 200 units and 800 MW of power, with average power rating per unit around 3 MW ** * source: R. DiPippo ** source: IGA 11

12 ORC Applications COOLING DEVICES ELECTRIC POWER OUTPUT ORC TURBOGENERATOR UNITS WATER CONDENSERS EVAPORATIVE TOWERS THERMAL USE (IF REQUIRED) EVAPORATIVE CONDENSERS AIRCOOLERS GEOTHERMAL HEAT SOURCE AIR CONDENSERS No standard heat/cooling sources highly customized solutions 12

13 The Thermodynamic Principle: the ORC Cycle GEOFLUID 3 4 Turbine Generator 5 Evaporator 2 1 COOLING MEDIUM ENTROPY GEOFLUID CIRCUIT Preheater Pump Condenser COOLING CIRCUIT The turbogenerator uses the geothermal water to pre-heat and vaporize a suitable organic working fluid in the evaporator (2 3 4). The organic fluid vapor powers the turbine (4 5), which is directly coupled to the electric generator through an elastic coupling. The vapor is then condensed in the condenser, cooled by water or air (5 1). The organic fluid liquid is finally pumped (1 2) to pre-heater and evaporator, thus completing the sequence of operations in the closed-loop circuit. 13

14 Why High Molecular Mass Working Fluid Instead of Water? Water Organic Fluid Small, fast moving molecules Metal parts and blade erosion Very large flow rate Larger diameter turbine Multistage turbine and high mechanical stress Smaller wear of blades and metal parts WATER HIGH MOLECULAR MASS FLUID 14

15 Advantages of Turboden ORC Turbogenerators Technical advantages High cycle efficiency Very high turbine efficiency (up to 90%) Operational advantages / results Simple start-stop procedures Automatic and continuous operation Low mechanical stress of the turbine due to the low peripheral speed Low RPM of the turbine allowing the direct drive of the electric generator without reduction gear No erosion of blades, thanks to the absence of moisture in the vapor nozzles No operator attendance needed Quiet operation Very high availability (Admont: over hrs of operation, availability > 98%) Partial load operation down to 10% of nominal power High efficiency even at partial load Low O&M requirements Long life 15

16 ORC Design Main issues to consider Corrosion special and costly materials for the heat exchangers great influence on the cost of the unit longer delivery period Scaling limits in cooling the geothermal brine Fouling removable covers and straight cleanable tubes Vapor plume and need for makeup water in case of evaporative devices Working fluid flammability: critical in urban areas & for insurance cost Cascade use / cogeneration: schemes, feasibility Larger footprint and noise emissions from the fans in case of air cooling 16

17 ORC Design Evaluation of the proper Cooling System: wet Vs dry WATER CONDENSERS EVAPORATIVE TOWERS EVAPORATIVE CONDENSERS AIRCOOLERS AIR CONDENSERS AVAILABL E MAKE UP WATER NOT AVAILABL E Evaporative towers Smaller footprint Lower noise emissions Fresh water consumption Chemical water treatment operation cost, environment Air condensers Larger footprint Higher noise emissions No water needed Virtually no environmental impact and operating costs Critical issues Investment costs: initial / overall Generated yearly output, linked to gross power and parasitic loads 17

18 ORC Design Most geothermal applications are for liquid dominated systems The geothermal fluid is preferably maintained in liquid phase 200 C Ideal Lorentz Cycle 150 Hence it is important to exploit efficiently the variable temperature heat source C Thermal Power C ORC: single evaporation pressure level Thermal Power C ORC: two evaporation pressure levels Thermal Power Geothermal Fluid Ideal Lorentz Cycle Thermal Pow er Organic Fluid 18

19 ORC Design 2 1 Geothermal GEOFLUID 3 4 COOLING MEDIUM 5 Evaporation temperature selection In Open Systems it is important to balance between thermodynamic cycle efficiency and geothermal system efficiency T Geofluid discharge temperature Geofluid inlet temperature P = Q in * η cycle η TOT = η geo * η cycle ENTROPY Entropy 19

20 ORC Design Working fluid selection is influenced by many factors Cost Enthalpy drop & flow rate Environmental friendliness Heat input curve Flammability Pressure levels Cooling system OPTIMAL FLUID changes from case to case 20

21 ORC Design Option to select a non flammable fluid Fluid flammability is critical in urban areas & for insurance costs The Altheim plant building Turboden identified and studied a number of fluids Turboden tested a non flammable fluid in Altheim, being used ever since Lab tests under way to check compatibility & behavior in wider range Possibility to place the unit inside a building or shelter (protection from atmospheric agents and mitigation of noise emissions) 21

22 Early Demonstration Projects Location: DAL Kapisya, Zambia Year: 1988 Heat source: Geothermal fluid at 88 C Total electric power: 2 x 100 kw Plant type: geothermal experimental for Enel Location: Castelnuovo Val di Cecina, Italy Year: 1992 Heat source: Geothermal fluid at 114 C (return at 102 C) Cooling source: water/air Total electric power: 1.3 MW Net electric efficiency: 9% 22

23 EU Funded Demonstration Project Plant type: geothermal low enthalpy, coupled with a geothermal district heating system Location: Marktgemeinde, Altheim, Austria Started up : March 2001 Heat source: hot water at 106 C Cooling source: cold water from a nearby river (cooling temperature 10/18 C) Design electric power: 1 MW (normally operated by the owner at ~ 500 kw el ) Plant type: geothermal, 1 st EU operating plant on EGS (Enhanced Geothermal System) Location: Soultz-sous-Forêts, Alsace, France Started up: 2 nd quarter 2008 Heat source: hot water at 180 C Cooling source: air Total electric power: 1.5 MW Net electric efficiency: 11.5% Plant type: geothermal low enthalpy, coupled with a geothermal district heating system Location: Simbach Braunau, German-Austrian border Started up: 3 rd quarter 2009 Heat source: hot water at 80 C Cooling source: air/water Design electric power: 200 kw 23

24 Commercial - Reference Plant Heat Recovery Water temperature similar to Geothermal Plant type: heat recovery from pressurized water boiler in waste incinerator Customer: MIROM Location: Roeselare, Belgium In operation since: 2 nd quarter 2008 Availability > 98% Heat source: hot water at 180 C (return at 140 C) Cooling source: water/air Total electric power: 3 MW Net electric efficiency: 16.5% Non flammable working fluid: to meet customer s requirement 24

25 Commercial Proposals 5 MW+ Geothermal ORC in Germany Plant type: geothermal ORC two evaporation pressure levels Heat source: hot water at 130 C (return at 50 C) Cooling device: aircondenser Total electric power: 5.4 MW el Net electric efficiency*: 10.1% Working fluid: refrigerant 30 MW Geothermal ORC in USA Plant type: geothermal ORC two evaporation pressure levels Heat source: hot water at 163 C (return at 70 C) Cooling device: evaporative towers Total electric power: 29 MW el Net electric efficiency*: 12.3% Working fluid: refrigerant * including aircondensers consumption Electric Generator: synchronous or induction, no reduction gear needed * excluding cooling towers consumption 25

26 Commercial - Turboden Solutions Hot water resource between 90 C and 180 C* Size from 1 MW el to 7 MW el Scalable for larger plants High cycle efficiency Enhanced cycle efficiency with two-level cycles Low O&M requirements Option to select non-flammable working fluids * 212ºF 356ºF 26

27 The PureCycle Power System Heat to Electricity Power Generation 280 kw el Gross Power Free fuel Zero emissions Renewable baseload power generation 90 C 150 C* resource range Modular and scalable for larger plants Short lead times 24/7/365 remote monitoring High availability * 195ºF 300ºF 27

28 Commercial Validation Chena Hot Springs in Alaska 1 st unit commissioned July nd unit December ºC* hot water resource 4-7 C** cooling water available > 98% availability to date * ~ 165º F ** ~ 40ºF 45ºF Drivers: Cost savings Off-Grid operation Baseload application Sustainable power 28

29 Utility Geothermal Application 10 MW+ Net Power Sold to California Utility UTC teamed with Raser Technologies Modular, scaled approach for rapid power plant Power will be sold under yr PPA s* Full time UTC service technicians on-site All units commissioned Developing multiple projects at several locations in Western US over the next several years * Power Purchase Agreement 29

30 Latest installation Oregon First geothermal power plant in Oregon commissioned in Aug 2009 Supplies 20% of the electricity for the campus ~ 195 F (~ 91 C) water Unit will produce ~ 175 kw el (summer) and ~ 200 kw el (winter) 30

31 Advantages Turboden + PWPS Maximizing value for customers Size flexibility 280 kw el to over 7 MW el High temperature capability Up to 180 C Low temperature capability Down to 90 C ORC Experience About 30 years High reliability 24 x 7 x 365 Remote Monitoring Modularity Factory assembled systems Aftermarket capability Worldwide Financial strength Backed by Pratt & Whitney and UTC Lead time 6 months for PureCycle systems months for Turboden units 31

32 Turboden Headquarters in Brescia 32

33 Geothermal Energy Exhibition - 1 st Edition 23 rd - 24 th - 25 th of September 2009 The ORC technology is a good option with further growth potential for small / medium scale geothermal applications We believe that Turboden and PureCycle ORC s are in a good position to exploit this potential Thank you for your kind attention! Turboden srl via Cernaia, Brescia - Italy Tel Fax info@turboden.it

34 Turboden Facts & Figures (Last update: January 2009) 34

35 Turboden Facts & Figures Orders value ( ) Production value ( ) Turnover ( ) in Foundation year 107 Employees 100 Plants in operation 50 The percentage growth of production value 08/ The percentage growth in turnover 08/ Engineers 33 Plants under construction 33 Average age of the employees 12 Countries that have at least one ORC Turboden 8 The percentage of investment in R & D 2 Offices (Brescia: headquarters, Milan: local office) 1 Ufo 22, Turboden s sailing boat PWPS acquires majority stake in Turboden - July 09 35