Application of Organic Rankine Cycle technology in Biomass plants 1-5 MW Eytan kaplan PowerGen Africa 2015 15 July 2015
INDEX SUMMARY The different ways to use Biomass for Power Comparison between Steam and ORC biomass systems The ORC Biomass solution Biomass power plant Biomass Potential in Africa Case studies About EXERGY & Other uses of ORC Geothermal Heat Recovery (engines / process) CSP
BIOMASS INTRODUCTION: the different ways to use Biomass for Power
ALTERNATIVE TECHNOLOGIES: 1) EFGT (External Fired Gas Turbine): High system efficiency No flexible feed: need to have a very clean biomass due to the problems on the heat exchanger Critical component: high temperature air/flue gas heat exchanger 2) Gassification (pyrolysis): High system efficiency No flexible feed: need to have a very high selected and pure biomass High cost of maintenance
ALTERNATIVE TECHNOLOGIES: 3) Screw/scroll steam expander: Low system efficiency No proven system reliability Lower flexibility at partial load due to the technology All these technologies have common issues: Low number proven commercial installations Poor reliability and availability results in operation No demonstration of the expected efficiency
PROVEN SOLUTIONS FOR BIOMASS 1) Biomass boiler and Steam Turbine: Efficient Proven 2) Biomass boiler and Organic Rankine Cycle System Efficient Proven Flexible
ORC vs. STEAM TECHNOLOGY - COMPARISON
ORC vs. STEAM TECHNOLOGY: OPTIMAL TEMPERATURE RANGE
BIOMASS POWER PLANTS: ORC SOLUTION Exergy solution for power generation from biomass is: ORC module + biomass boiler This solution has many advantages: Good compromise between investment cost and efficiency High reliability thanks to proven technology High flexibility in biomass feed quality High modularity and simple installation Few civil works required
ORC BIOMASS PLANTS Details
ORC BIOMASS SOLUTION System description: The boiler through the combustion process converts the biomass in thermal power to feed the ORC module. The hot exhaust gas warms up the intermediate fluid in a heat exchanger ORC/boiler interface circuit transfers the thermal power from the boiler to the ORC evaporator Usually the intermediate fluid between boiler and ORC are: thermal oil pressurized water steam EXERGY developed solutions with either thermal oil or saturated steam for different applications
ORC BIOMASS SOLUTION System description: The interface fluid transfers heat to the organic fluid in the ORC evaporator, where the organic fluid vaporizes The ORC module produces : Electrical power: expanding the vapor in the turbine Thermal power: discharging the medium temperature heat contained in the vapor at turbine outlet Thermal power can be utilized for cogeneration purposes: Cogeneration for industrial processes District or residential heating Trigeneration (production of warm and cold streams for heating and cooling purposes)
BIOMASS FEED The biomass feed of the boiler can be very flexible Saw dust maximum 50% in volume per unit of charge Wood chips P100 Ground wood P300 with max section 50x50 mm Bark max dimensions 300x10x20mm Wood industry waste Forestry waste Coal maximum section 30x30 mm Olive waste and other secondary biomass* * It may be necessary to mix it with wood chips to stabilise the feed
PROCESS FLOW DIAGRAM
TYPICAL PLANT LAYOUT SMALL SIZE (200-300 kwe)
TYPICAL PLANT LAYOUT MEDIUM SIZE (1-3 MWe)
ORC PACKAGE Recuperator
BIOMASS PLANTS: TYPICAL SOLUTIONS PLANT 1 MWe OIL 2 MWe OIL 4 MWe OIL Thermal oil /steam inlet temperature C 310 310 310 Thermal oil outlet temperature C 240 240 240 Cogeneration water temperature C 80-100 80-100 80-100 Gross Power kwe 1000 2000 4000 Average number of houses supplied n. 350 700 1400 Gross efficiency (with/w.out cogeneration) % 19/24 20/25 20/25 Biomass consumption (PCI = 2400 kcal/kg) ton/year 17000/14000 33000/27000 66000/54000
Biomass potential in Africa
BIOMASS IN AFRICA BIOMASS IN AFRICA Largest populations in sub-saharan Africa relying on traditional biomass for cooking, 2012 Based on International Energy Agency (IEA) data
BIOMASS IN AFRICA BIOMASS IN AFRICA Reliance on fuelwood and charcoal remains high, even as incomes grow; 650 million people still cook with biomass in an inefficient & hazardous way in 2040 Based on International Energy Agency (IEA) data
BIOMASS CASE STUDIES
BIOMASS CASE STUDIES Plant Type: Model: Client: Location: Biomass EP 110 ERS 1MWe Energia Vulture Alto Bradano Venosa, Italy
BIOMASS CASE STUDIES REQUIREMENT OF THE CLIENT 1. Dispose of waste from grape and olive production and waste from local wood processing industry 2. Developing a secondary revenue stream by selling electricity back top the grid QUANTITY OF BIOMASS 16000t/y ELECTRICAL EFFICIENCY OF THE ORC 24% ELECTRICAL GENERATION GROSS 990 KWE THERMAL MEDIUM THERMAL OIL 300-200 C WATER COOLING AGENT DIRECT AIR COOLING GENERATION VOLTAGE 400 V INSTALLATION OUTDOOR
BIOMASS CASE STUDIES Plant Type: Biomass Model: HREX 110 Client: Del Tongo Location: Arezzo, Italy
BIOMASS REFERENCES CASE STUDIES HEAT RECOVERY FROM BIOGAS ENGINES Plant Type: Model: Power: Client: Location: HR BIOGAS EP10 POWERBOX 100 kwe Marsica Bioenergie Celano, Italy
ABOUT EXERGY
ABOUT EXERGY & OTHER USES of ORC: EXERGY designs, manufactures, supplies and operates Organic Rankine Cycle (ORC) systems for: GEOTHERMAL WASTE HEAT RECOVERY (FACTORIES/ ENGINES) BIOMASS SOLAR (CSP) EXERGY are unique in having the extremely efficient organic Radial Outflow Turbine.
EXERGY is the pioneer of ORC Radial Outflow technology. EXERGY undertake: Development and manufacturing of the ORC turbine and plant internally Testing Engineering Project management After Sales service Size range: between 0.1 10 MW on a single turbine EXERGY is a subsidiary of the SECI Maccaferri Industrial Group within the SECI S.p.A holding. Offices Across the globe and AFRICA. 5000 Employees
Designed and patented by EXERGY, the Radial Outflow Turbine is unique in the ORC marketplace. The idea was first conceptualized by EXERGY CEO Claudio Spadacini. The Radial Outflow Turbine is capable of converting the energy that is contained in the fluid with higher efficiency than competing technologies on the market.
REFERENCES REFERENCES HR FROM STEEL MILL: Plant Type: HR steel Model: EPSd 110 Power: 1000 kwe Client: ABS - Danieli Location: Udine, Italy
REFERENCES REFERENCES GEOTHERMAL : Plant Type: Geothermal Model: GEX 110 Client: Enel Green power Location: Bagnore, Italy
REFERENCES REFERENCES GEOTHERMAL : Plant Type: Geothermal Model: GEX 2300 Power: 22.5 MWe Client: Celikler Hodling Location: Pamukoren, Turkey
EXERGY S.p.A T: +39 0331 1817 611 F: +39 0331 1817 723 E: info@exergy.it W: www.exergy-orc.com Head Office: via Santa Rita 21057 Olgiate Olona (VA) Italy Legal Office: Via degli Agresti, 6 40123 Boliogna (BO) Italy