ORC technology and its applications to the RE sector Marrakesk, November 15 th 2016 Cem Zulfikar Business Developer
ORC: 130 Years of History The first ORC, featuring a reciprocating expander, fed by a hydrocarbon (naphta) vaporized Patent of Frank W.Ofeldt, 1886-1887 35 kw ORC unit CSP plant in Perth, 1984 2
Temperature Organic Rankine Cycle: Thermodynamics Turbine Electric Energy Generator Heat carrier Evaporator Pre-heater Cooling medium Entropy Pump Condenser The turbogenerator uses the heat carrier (e.g. 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 or other) (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. 3
ORC TURBOGENERATORS ARE SIMPLE, FLEXIBLE AND RELIABLE WORK AT LOW TEMPERATURES (90+ C) LOW O&M* SIMPLE NO NEED OF WATER HIGH FLEXIBILITY AND GOOD EFFICIENCY AT OFF DESIGN CONDITIONS AUTOMATIC AND CONTINUOUS OPERATION ** RELIABILITY * Few personnel required and no water treatment needed ** Simple start-stop procedures
Source: ESMAP Geothermal Handbook, 2012 Copyright Turboden S.r.l. All rights reserved ORC BINARY PLANTS EXPLOIT LOW-TEMPERATURE RESOURCES TYPE TEMP C GEO SOURCE SINGLE FLASH DOUBLE FLASH >150 Suitable if the resource has high steam quality and low NCG content Suitable if the resource has low steam quality and low NCG content BINARY <200 Favorable with both only hot water and water/steam mixture DRY STEAM >200 Favorable if the resource has very high steam quality 23 % global market share BACK PRESSURE >150 Favorable if the resource has high steam quality and reinjection is not required ADVANTAGES OF BINARY Low enthalpy Total reinjection (closed loop) Simple start-stop procedures Low O&M costs
ORC PROVIDES AN EFFICIENT ENERGY SOLUTION TO RECOVER WASTE HEAT Industrial processes, i.e. Cement Steel Glass Non-ferrous metals Oil&Gas, i.e. Gas compressor stations Flare gas Refining process Water-Free Combined Cycles, i.e. Reciprocating engines Gas turbines
ORC PLANTS FED BY SOLID BIOMASS CAN PROVIDE HEAT FOR DIFFERENT THERMAL USES Solid biomass fuels Wood biomass: sawdust, wood chips, bark, treated wood Agricultural residues: green cuttings, corn cob, rice husk, olive husk, cotton residues etc Confidential for internal use only Heat consumers District heating network Timber drying Sawdust drying for wood pellet MDF/ panel industry Greenhouse/wine industry Combined cooling heating power (CCHP)
Turboden ORC in biomass application panel industry By application BIOMASS REFERENCES Combined Heat and Power (CHP) 158 sawmill and wood industry CCHP* in buildings 5 Other 116 TOT. 279 pellet District heating 2-3 MW By size > 3 MW CCHP* power only 1-2 MW 0,2-1 MW * Combined Cooling Heating Power 8
specific cost ( /kwh) CSP applications Solar energy can be harnessed by different technologies. Each of the technologies covers the part of the market where it can bring the highest costeffectivness rate. Turboden ORC mostly finds its place in industrial scale sector from 1 to 10 MW e Residential scale (up to 1 MW) Industrial scale (up to 10 MW) Utility scale (from 50 MW) 9
CSP applications The ORC power block uses organic fluid to drive the turbine instead of a traditional high pressure steam. This results in a reliable, efficient and user friendly solar thermal power plant 10
CSP applications - the first commercial project of Turboden in Morocco Customer: Italcementi Group Site: Ait Baha, Morocco DNI: 2,400 kwh/m 2 _year Turboden unit: Turboden 18 HR (2 MW e ) Figure 5: Turboden 18 HR in Ait Baha plant Figure 5 Figure 6 Plant type: hybrid heat recovery from waste heat of cement factory plus solar collectors with pebble stone thermal storage Figure 6: Airlight conctrete solar collector structure Figure 7: view of Italcementi cement factory in Ait Baha with solar field Figure 7 Solar field area: Aperture area: 6,159 m 2 Nr. of string: 3 String length: 215 m Thermal power: 4 MW th Storage capacity: 12 h HTF: hot air
CSP applications- reference ENAS project Final Customer: ENAS (Ente acque della Sardegna) Site: Ottana (Nuoro, Sardegna) Size: 650 kw el Turboden unit: Turboden 6 HR (Nominal working conditions: thermal oil 260/150 C, cooling water 25/35 C, gross efficiency 21%) Plant type: pure solar plant with 6 loops FERA Fresnel solar collectors (about 10.000 m 2 ) and a direct two-tanks thermal oil storage with thermal capacity of almost 5 equivalent working hours Figure: FERA Fresnel solar collectors. 12
CSP applications- reference Archimede project Final Customer: Archimede S.r.l. Società di Ingegneria Site: Melilli (Siracusa, Sicilia) Size: 1180 kw el Turboden unit: Turboden 12 HRS (Nominal working conditions: thermal oil 305/204 C, cooling water 25/35 C, gross efficiency 25%) Plant type: hybrid solar plant with about 8.000 m 2 collectors coupled to a 3 MW th natural gas boiler. solar Figure: Turboden 12 HRS 13
CSP applications - R&D Solar project (2008-2014) Research project granted by the Italian Minister of Research and University. Scope of the project is the realization of small scale ORC prototype of 200 kw connected to a solar field in the University of Lecce (Italy) 14
CSP applications - Development Five 4 MW plants are under development in Sicily Nominal capacity: 4 MW el Thermal storage: 20 MWh Energy production: 8000 MWh el Solar surface: 49.490 m 2 Land occupancy 10 ettari
Key recommendation The ORC technology Hybridization with other renewables or waste heat from industrial processes Possible combination with desalinisation processes Best solution for off-grid small/medium scale plants Best solution for small/medium scale plants to be installed on sunny islands 16
Thank You Cem Zulfikar Business Developer cem.zulfikar@turboden.it