ilaria peretti (turboden) – turboden's orc turbogenerator in the

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Turboden's ORC Turbogenerator in the Pellet Industry Halifax, Nov 4th, 2015 Ilaria Peretti – Manager, Sales & Business Development North America

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Page 1: Ilaria Peretti (Turboden) – Turboden's ORC Turbogenerator in the

Turboden's ORC Turbogenerator in the Pellet Industry

Halifax, Nov 4th, 2015

Ilaria Peretti – Manager, Sales & Business Development North America

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•  Prof. Mario Gaia makes experience in the field of ORC within his research group at Politecnico di Milano

•  1976 – First prototype of a solar thermodynamic ORC

’60-­‐’70   1980-­‐1999   2000-­‐2009   2009-­‐2013   2013…  

•  1980 – Prof. Mario Gaia founds Turboden to design and manufacture ORC turbogenerators

•  Turboden develops research projects in solar, geothermal and heat recovery applications

•  1998 – First ORC biomass plant in Switzerland (300 kW)

•  Turboden installs ORC biomass plants, especially in Austria, Germany and Italy

•  Turboden plans to enter new markets, with focus on North America

•  First heat recovery applications

•  2009 – Turboden achieves 100 plants sold

•  United Technologies Corp. (UTC) acquires the majority of Turboden’s quota. PW Power Systems supports Turboden in new markets beyond Europe

•  UTC exits the power market forming strategic alliance with Mitsubishi Heavy Industries

•  PW Power Systems becomes an MHI group company

More than 30 Years in ORC

•  MHI acquires the majority of Turboden. Italian quotaholders stay in charge of management

2015…  

 More  than  300  plants    

in  32  countries    and  410  MW  installed  

 

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The Organic Rankine Thermodynamic Cycle

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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  elasJc  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   compleJng   the   sequence   of  operaJons  in  the  closed-­‐loop  circuit.  

Turbine  

Generator  

Pre-­‐heater  

Cooling  medium  

Condenser  

Evaporator  

Pump  

Heat  carrier  

Electric  Energy  

Tempe

rature  

 

Entropy  

   

   

Cooling  medium  

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VIDEO Turboden ORC Cycle

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Turboden ORC cycle.wmv

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Turboden has more than 300 ORC plants worldwide...

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Nechako  Green  Energy    (a  subsidiary  of  Nechako  Lumber)    Site:  Vanderhoof,  BC,  Canada  ORC  Unit:    Turboden  22  CHP  Started  up:  Feb  2013    Electric  power  generated:  2  MW  Thermal  power  applicaRon:    hot  water  temperature  (60-­‐90  °C)  for  future  belt  dryer  connecJon    

Reference projects Canada and USA

West  Fraser  Timber    2  Sites:  Chetwynd  and  Fraser  Lake,  BC,  Canada  ORC  Unit:  4  x  units  Turboden  65  HRS  (high  efficiency  up  to  26  %)    Started  up  :  Nov  2014  Electric  power  generated:  13  MW  each  site  (total  of  26  MW)    

Manning  Diversified  Forest  Products  Ltd  Site:  Manning,  AB,  Canada  ORC  Unit:    Turboden  32  HRS  (high  efficiency  up  to  26  %)    Started  up:  Feb  2015  Electric  power  generated:  3  MW      

Furthermore,  2  heat  recovery  projects:  

Ø  1  MW  from  Heat  Recovery  of  a  gas  turbine  in  a  Gas  Compression  StaJon  (IST  -­‐  TransGas)  in  Rosetown,  SK,  Canada.  Started  up:  Dec  2012  Ø  1  MW  from  Heat  Recovery  of  a  sludge  waste  incinerator  in  Menands,  NY,  US.  Started  up:  Jan  2013  

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Turboden Experience in Pellet Production

Turboden  counts  28  ORCs  in  operaRon  integrated  in  a  pellet  making  process  and  other  7  are  under  construcRon  

•  In  total  more  than  1  Million  hours  worked  in  pellet  integraJon  mode    •  40  MWel  installed  and  30  MWel  more  under  construcRon  

 

Countries  where  Turboden  ORC  is  integrated  in  a  pellet  making  process  are:  Germany,  Austria,  Italy,  UK,  Spain,  CroaJa,  Russia,  Poland,  US  and  Canada.  

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Pellet process and Turboden ORC integration

ORC  Flexibility   and  Reliability

Pellet  Manufacturing  Process  

The  integra5on  between  the  Turboden  ORC  and    an  exis5ng  or     brand  new  Pellet  manufacturing  process  gives  the  possibility  to

diversify  the  business   producing,  at  the  same  5me,  Pellet  and  Electrical  Energy  from  

Renewable  Sources  (i.e.  biomass)

Industrial  process produc5vity  needs

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Wood Pellet Production with Belt Dryer

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BELT DRYER

Pellet PELLET

READY TO BE PACKAGED

Suitable granulometry

UR 40%

UR < 13%

BIOMASS POWERED

BOILER

SELECTION/ SORTING

CHIPPING BARKING

AIR COOLING/ DEDUSTING

PELLET MAKING PRESS

ORC

DEDUSTING/ SELECTION/

REFINING

MILLING

Thermal oil

Electric power

TRUNKS

cold water

hot water

•  CHP  units  produce  hot  water  which  can  be  used  into  a  belt  dryer; •  No  changes  in  the  pellet  making  process;

•  Produc5on  of  pellet  and  Electrical  Energy;

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Model:  Turboden  30  CHP  Start-­‐up:  under  construcJon,  expected  start-­‐up  Jan  2016  LocaRon:  Chetwynd,  BC,  Canada  Fuel:  hog  fuel  ORC  Electric  power:  3  MW  ORC  thermal  power:  14  MW  Belt  dryer  fed  by  water:  In/out@  77/110°C  Thermal  Power  to  dry  sawdust  from  50%  to  8%  Capacity  Pellet  producRon:  13  ton/hr    ORC  electric  power:  3  MW  ORC  thermal  power:  14  MW  Water  temperature:  60  –  90  °  C  Biomass  boiler:  16,675  kW  Pellet  producRon  capacity:  80,000  t/y  

Canfor/Pacific Bioenergy Reference

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Wood Pellet Production with Rotary Drum Dryer

-­‐  Turboden  High  Efficiency  ORC  units  

produce   hot  water  at  low  

temperature  which  can  be  used  by  

a  low  temperature  user  (green  houses,  swimming  pools  …);

-­‐No  changes  in  the  

pellet  making  process;

-­‐  Produc5on  of  Electrical  Energy  at  high  efficiency  and  

Hot  water

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Maine Woods Pellet reference

Athens Energy LLC (subsidiary of Maine Woods Pellet Company LLC)

•  Site: Athens, Maine, US •  ORC Unit: Turboden 80 HRS •  Status: under construction, expected start-up Feb 2016

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MAINE WOODS PELLET CO. LLC

q  Fuel:  wood  chips  q  Heat  carrier:  thermal  oil  q  ORC  working  fluid:  hydrocarbon  q  ORC  electric  power:  8  MW  q  Electric  Efficiency:  25%  

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Turboden CHP in Pellet manufacturing process with ROTARY Drum Dryer

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**Assuming  Turboden  CHP  and  Belt  dryer  configura5on

• Source:  Bioenergy  Interna;onal  May  2011, Prodesa  Medioambiente  –   “Cogeneracción  y  producción  de  pellet”

Sample  case:**

• ORC  Unit:  Turboden  10  CHP  integrated  in  a  Pellet  plant

• Pellet  produc5on  capacity  =  4  tons/h

• Pellet  produc5on  =  30,000  tons/y

• Biomass  Consump5on  =  57,500  tons/y

• Boiler  installed  =  5.2  MWth

• Electrical  power  installed  =  1  MWel

• Thermal  power  output  =  4.1  MWth  at  inlet/oultet  water  temp.  60/80°C

Dimensioning Parameters

ORC  Size   Pellet  producRon  capacity    (dry  product)**  

1  MWel  and  4  MWth   30,000  t/y*  

3  MWel  and  13  MWth   85,000  t/y  

5  MWel  and  22MWth   150,000  t/y  

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Turboden ORC in Pellet manufacturing process

Technical  feasibility  vs  Economical  feasibility The  best  configura5on  for  an  integrated  plant  strongly  depends  on  the  boundary  condi5ons.

Turboden Seminar on ORC Technology Relaisfranciacorta, Corte Franca - November 16-17 2011

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Advantages from Turboden ORC + Pellet

1)  The  Turboden  ORC  does  not  lead  to  significant  changes  to  the  conven5onal  heat  only  plant  for  pellet  produc5on;

2)     The  high  flexibility  of  the  Turboden  ORC  can  follow  thermal  

request  of  the  pellet  manufacturing  process.  

3)      The  Turboden  ORC  adds  value  to  an  already  available  source; 4)    The  Turboden  ORC  allows  the  diversifica5on  of  the  business  to  

gain  a  second  and  safe  source  of  income;

Tech

nica

l E

cono

mic

al

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Ilaria Peretti– Manager, Sales & Business Development North America

[email protected]

Thank you for your attention!