turboden orc energy recovery: best practices in energy ...hreii.eu/demo/public/turboden-eeip...

Turboden ORC energy recovery:best practices in energy intensive industries

Alessandro Foresti – Turboden Director

Energy recovery in industry – Best practice to implemen tionDuisburg, Wednesday 12th June 2013

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• ORC technology

Features and advantages

• About Turboden

30 years of experience

• Application

Turboden ORC references

H-REII and H-REII Demo: Demonstration WHR plant in steel industry

• References in Energy Intensive Industries

Interface with process

References

First glance at economics

• Conclusion

Agenda

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� standard units from 200 kW to 10 MW

� customized solutions up to 15 MW

� standard units from 200 kW to 10 MW

� customized solutions up to 15 MW

3

electricity

heat

Biomass

Waste-heat

Geothermal

Solar

Turboden ORC

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The Thermodynamic Principle: The ORC Cycle

The turbogenerator uses the hot temperature thermal oil to pre-heat and vaporize a suitable organicworking fluid in the evaporator (8→3→4). The organic fluid vapor powers the turbine (4→5), which isdirectly coupled to the electric generator through an elastic coupling. The exhaust vapor flows throughthe regenerator (5→9) where it heats the organic liquid (2→8). The vapor is then condensed in thecondenser (cooled by the water flow) (9→6→1). The organic fluid liquid is finally pumped (1→2) to theregenerator and then to the evaporator, thus completing the sequence of operations in the closed-loopcircuit

Turbine

Generator

Rigenerator

Water

Condenser

Evaporator

Pump

Heat carrier

Electric EnergyTe

mp

era

ture

Entropy

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ORC vs. traditional steam cycle

5

Water / Steam

Tem

pera

ture

Entropy

Tem

pera

ture

ORC

Entropy

SATURATION CURVE WITH PARALLEL SLOPES

Dry vapour expansion

No need to superheat

Moderate temperature/pressure

SMALL ENTHALPY DROP

Large slow turbine Rigeneration

High efficiency

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Advantages of Turboden ORC Heat Recovery Plants

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• No erosion of blades, low mechanical stress of the turbine

• No corrosion issues (use of non aggressive working fluid)

• Ease of integration in main process (by-pass); do not affect plant operations

• Demonstrate very good partial

load behaviour (see curve)

• Do not consume water

• No need of water treatment

• Selection of more appropriate

working fluid

• Low O&M requirements

• ORC plants remotely monitored 20%

30%

40%

50%

60%

70%

80%

90%

100%

0% 20% 40% 60% 80% 100%

OR

C A

ctu

al

Eff

icie

ncy

/ O

RC

No

min

al

Eff

icie

ncy

Actual Load / Nominal Load

ORC Part Load efficiency

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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

• First direct exchange ORC 600 KWeconnected to Diesel Engine

• 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

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

•Today - Over 250 ORC plants in the world, 200 in operation

Over 30 years of experience

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Oil&Gas Player

Russia

Oil&Gas Player

Canada

8

In Europe

Germany 80

Italy 71

Austria 30

Spain 7

etc…

Turboden ORC units in the world 253 - 28 Countries

Installed power 333 MW

Wood Biomass 221 units (300 kW ÷ 6.5 MW)

Combined cycles 13 units (500 kW ÷ 4.5 MW)

Industrial heat recovery 9 units (700 kW ÷ 7 MW)

Municipal waste treatment 4 units (500 kW ÷ 6 MW)

Geothermal 6 units (1 MW ÷ 6 MW)

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A good energy efficiency practice: decrease final

energy consumption (electricity, heat, etc.)

recovering EII waste heat streams

ORC generator

process or thermal

users: both civil and industrial

Heat Exchanger

Energy Intensive Industries

wasted heatgas, liquid,

vapour

Electricity

Thermal energy

Thermal Energy

ORC Heat Recovery in Energy Intensive Industries

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ORC interfaces with the process

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ORC battery limit

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Interfaces with process: heat carriers

Heat carriers:• Thermal oil• Saturated steam• Water (e.g. geothermal, moderate temperature heat recovery)• Molten Salts (e.g. CSP)• …

Heat carrier loop features :• Multiple heat sources• Layout flexibility• Ease of operation (process upset tolerance)• Energy buffer• …

Direct heat exchange with hot gas stream is feasible,under certain conditions…

Layout, heat exchanger size, 1 source to 1 ORC, etc.

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Heat Recovery In Energy Intensive Industries: Turboden approach

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Several schemes can be studied to maximize electric power output

minimizing the investment cost

Collaboration with process owner and heat exchanger suppliers to best

match the specific plant features

Flexible ORC solutions :

• different working fluids (temperature ranges, ORC size, etc.)

• different heat carriers (temperature ranges, specific issues, etc.)

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Holcim Slovakia– Holcim GroupSite: Rohoznik (Slovakia)

Client: Holcim Slovensko A.S.

Status: to be started up end 2013 / beginning 2014

Heat Source: exhaust gas from PH and CC

Heat carrier: thermal oil

Cooling: water condenser + wet cooling tower

Electric power: 5 MWel

Slovakia

Holcim Romania – Holcim GroupClient: Holcim Romania - Alesd

Clinker production capacity: ≈ 4.000 ton/day

Heat source: exhaust gas @ 360°C (PH) and hot air @ 250 °C (CC)

Thermal oil (PH) and pressurized water (CC) heat re covery loops


ORC electric power: ~ 4 MWe

Started up: July 2012 (4,200 working hours)

Availability: >98%

Turboden Heat Recovery references

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Cimar - Italcementi GroupSite: CIMAR – ITALCEMENTI GROUP (Morocco)


Heat source: PH exhaust gas at 330°C

Cooling: water condenser + air-coolers No water consumption

ORC electric power: 2 MWe

In operation since IV quarter 2010

Working hours: 16.000 h

Availability: >98%

The plant is being hybridized with CSP (Concentrated Solar Power) taking

advantage of the ORC extra capacity


AGC Glass EuropeSite: Cuneo - Italy

Client: GEA Process Eng

Final Client: AGC Glass Europe

Started up: March 2012

Heat source: gas @ 500°C from glass production process

Heat carrier: thermal oil

Cooling: water condenser + air-coolers

Electric power: 1.3 MWel

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Refractories – RHI Group Austria

Client: RHI GROUP (Radenthein - Austria)Refractory production capacity: ≈ 250 ton/day Heat source: refractory ovens exhaust gas @ 500 °CGas cooled down to ca. 150 °CORC electric power: ca. 1 MWeStarted up: Q1 2009


Pipeline compressor stationHeat recovery from Solar CENTAUR gas turbine in a Gas Compressor station in CanadaGas Turbine prime power: 3.5 MWeGas Turbine efficiency: 28%ORC electric power: 1MWe General Contractor: IST (Innovative Steam Technologies)Final Client: TransGasIn operation since IV quarter 2011

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Billet reheating furnace at steel rolling mill

Client: NatSteel – Tata GroupSite: SingaporeStarted up: February 2013

Heat source: exhaust gas from LFO combustion, @ 400°CDirect exchange between exhaust gas and working fluid ORC electric power: ~ 0.7 MW

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Heat Recovery Reference in Steel Industry -Direct exchange

4th Direct exchange ORC unit in operation

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� H-REII (2010-2012) �Quantify the heat recovery potential inthe Italian EIIs (pioneer EU project)�Promote energy efficiency policy inItaly (disseminating best practice)

Extending from Italy to Europe

� H-REII DEMO (2012-2014)�Quantify the heat recovery potential inthe European EIIs�Promote energy efficiency policy inEurope (disseminating best practice)�Support demonstration of ORC heatrecovery plant in the Steel Industry

European Focus on Energy Efficiency:H-REII and H-REII DEMO projects.

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Expected start up:

Q1 2014Electric Arc

Furnace(EAF)

Heat exchanger

Industrial thermal userThermal energy

~ 30 t/h steam at 27 bar - 245°C

Exhausted gases

ORC3 MWe

Electric energy

Reduce consumption

33%67%

H-REII Demo – Demonstration Plant

ESF - Riesa (Germany)

Tenova RE Energy

GMBH

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First glance at economics: CAPEX / OPEX

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ORC unit� ORC module is only a portion of the waste heat

recovery system � Specific investment cost depends on several

factors, most importantly the ORC size , but also specific applications , Client’s requirements and needs , cooling system, etc.

� ORC only OPEX in the range of 2-5 % of ORC Capex / year

Process heat exchanger, heat carrier loop and balance of plant

Specific investment cost highly affected by project-related and site-related factors, such as:

• Main process characteristics • Potential multiple heat sources• Layout constraints • Climate conditions at the installation site• Grid connection (voltage, distance) • Civil works• Erection cost• …

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Recomended policy actions:

• funding and guarantees to reduce barriers in project financing

• preferential prices for EII must promote investments for energy efficiency

• dissemination : increase industrial players awareness of BAT (ORC, etc.)

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Barriers and Prospects

ORC waste heat recovery in European EII is a best practice:

• of energy efficiency for a sustainable industry

• increasing industries competitiveness

• promoting a new European supply chain to export

• helping in saving/creating new jobs

… but investment payback time is limited by:• investment cost • electricity price with preferential rates for EII in some countries• Incentives for energy efficiency in industry only in few Member States• lower operating hours due to economic downturn

Thanks for your attention!

For further information contact:

[email protected]@turboden.it

+39 030 3552001www.turboden.com

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Backup

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ORC: Organic Rankine Cycle

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CONDENSER

FEED PUMP

EVAPORATOR

ORC broad definition: «a cycle with a change of phase (liquid to vapour and viceversa)

utilizing a working fluid different from Water …(hence including siloxanes,

hydrocarbons,…)»

EXPANDER

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• Cycle efficiency

• ORC Size

• Cost

• Safety

• Environment

Silicone based

•Small ORC size (<4 MWe) •Biomass• Moderate & high temperature HR (e.g. gas turbine exhaust, process waste gas)• Concentrated solar power

Fluorinated

• Geothermal• Low temperature HR (e.g. engine jacket water, process hot water)

•Big size of unit•Low cost, but some of them more flammable• Low, moderate & high temperature HR andbig biomass plants• Geothermal

Hydrocarbons

SOURCE TEMPERATURE

ORC Working Fluids

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Organic Fluid vs. Water

Water

� Small, fast moving molecules

� Metal parts and blade erosion

� Multistage turbine and high mechanical stress

Organic Fluid

� Very large flow rate

� Larger diameter turbine

� No wear of blades and metal parts

WATER HIGH MOLECULAR MASS FLUID

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Turboden – a group company of MHI

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EnergyAircraft Ship & OceanSpace

Transportation Material Handling Environment Automotive

Industrial Machinery Infrastructure Living & Leisure Defense

Mitsubishi Heavy Industries is one of the world's leading

heavy machinery manufacturers, with

consolidated sales of over $28 billion (in fiscal 2011).

MHI's products and services encompass shipbuilding,

power plants, chemical plants, environmental equipment,

steel structures, industrial and general machinery, aircraft,

space systems and air-conditioning systems.

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Turboden, more than 30 years in the ORC

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40 kW solar 3 kW CHP biomass

1987

3 MW waste incinerator

2008

Cement factories up to 7 MW

2013

Application in cement up to 7 MW

Perth, Australia Milan, Italy

Roeselare, Belgium Alesd, Romania

From small R&D modules to large industrial installations

1984

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Turboden – Facts & Figures

(Last update: January 2013) 28

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References in Renewables 1/2

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Site: British Columbia (Canada)Client: West Fraser TimberStatus: under construction Heat Source: biomass furnace burning wood chipsHeat carrier: Thermal oil Electric power: 2 sites with 2 x 6.5 MWel

Net electric efficiency: ∼25%Remote Locations

Plant type: geothermal prototype with supercritical cycle

Client: Enel Green Power - Italy

Started-up: March 2012

Heat source: hot water at 150°C nominal

Cooling device: ‘dry & spray’ condenser

Electric power: 500 kWel

Working fluid: refrigerant

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Client: SWM - StadtWerke München (public utilities company)

Site: Bavaria, Germany

Started-up: February 2013

Heat source: geothermal fluid at 140°C

Cooling device: air condensers

Electric power: 5+ MWel plus 4 MWth decoupling for

district heating


References in Renewables 2/2

Client: Hochtief Energy Management GmbH

Sites: Dürrnhaar (München)

Kirchstockach (München)

Started-up: December 2012 and March 2013

Heat source: geothermal fluid at 138°C

Cooling device: air condensers

Total electric power: 2 x 5,600 kW


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ORC heat recovery applications

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Industrial heat recovery demands ORC can guarantee

Main process reliability must not be

affected

Process interface with easy decoupling

Plant operators must not be

distracted

Simple, fail-safe and automatic system

Matching actual working regimes

(variable, semi-batch, upset)

Flexible / modulating operation

+ suitable process heat capture and transfer equipment

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References in heat recovery on industrial process

Site: Ankara (Turkey)Client: ITC-KA Enrji Uretim Sanayi Ve Ticaret A.S.Status: unit to be started up IV quarter 2013Heat Source: waste gasifierHeat carrier: t hermal oilCooling: water condenser + wet cooling towerElectric power: 5.5 MWelNet electric efficiency: ∼25 %

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Site: Cuneo - ItalyClient: GEA Process Eng Final Client: AGC Glass EuropeStarted up: March 2012Heat source: gas @ 500°C from glass production

processHeat carrier: thermal oil Cooling: water condenser + air-coolersElectric power: 1.3 MWel

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References in heat recovery and combined cycle

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Site: Pisticci Scalo (Italy)Client: Ricciarelli S.p.A.Started-up: June 2012Heat Source: 3x17 MW Diesel engines, gas @ 350°CHeat carrier: thermal oil Cooling: water condenser + wet cooling towerElectric power: 3.8 MWel

Project description: 3 thermal oil boilers recover heat from exhausts coming from palm oil-fed reciprocating engines.

Site: Roeselare-Belgium

Client: MIROM

Started up: II quarter 2008

Heat source: municipal solid waste incinerator

Heat carrier: pressurized water at 180 °C (back 140 °C)

Cooling: water condenser + air coolers

Electric power: 3 MWel

Net electric efficiency: 16,5%

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Heat recovery from Solar CENTAUR gas turbine

General Contractor: IST (Innovative Steam Technologies)Final Client: TransGas

Site: Rosetown - Saskatchewan, Canada

In operation since November 2011

�Gas Turbine prime power: 3.5 MWe

�Gas Turbine efficiency: 28%

�ORC heat carrier: thermal oil

�ORC electric power: 1M We

Gas compressor station

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Refractory

Heat recovery from refractory ovens exhaust gas

Client: RHI GROUP Site: Radenthein, Austria

In operation since February 2009

�Refractory production capacity: ≈ 250 ton/day

�Heat source: exhaust gas @ 500 °C

�Gas cooled down to ca. 150 °C

�Heat carrier: thermal oil

ORC electric power: ca. 1 MWe

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Billet reheating furnace at steel rolling mill

Client: NatSteel – Tata GroupSite: Singapore, Thailand

In operation since February 2013

� Heat source: exhaust gas from LFO combustion, @ 400°C

� Direct exchange between exhaust gas and working fluid

� ORC electric power: ~ 0.7 MW

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Steel

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H-REII DEMO:

Demonstration plant

Client: ESF Elbe Stahlwerke Feralpi GmbH Site: Riesa, Germany

Expected start-up within I quarter of 2014

Heat recovery on Electric Arc Furnace (Batch process)Heat source: ~ 20 tons/h saturated steam at 27 bar @ 245°CElectric power : 3 MW

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ORC

200 - 900 °°°°C

150 - 350 °°°°C

300 - 1600 °°°°C

Target:3-5% of the

EAF installed power

Industrial thermal user

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Client: Holcim Romania - Alesd


Heat source: exhaust gas @ 360°C (PH) and hot air @ 250 °C (CC)

Thermal oil (PH) and pressurized water (CC) heat re covery loops


ORC electric power: ~ 4 MWe

Started up: July 2012 (4,200 working hours)

Availability: >98%

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Romania

PH boiler AQCboiler

Reference case: Holcim Romania

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Reference case: Holcim Slovakia

Site: Rohoznik (Slovakia)Client: Holcim Slovensko A.S.Status: to be started up end 2013 / beginning 2014Heat Source: exhaust gas from PH and CCHeat carrier: thermal oilCooling: water condenser + wet cooling towerElectric power: 5 MWel

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Project description: The Rohoznik cement plant has a clinker capacity of around 3600 ton/day. Heat is recover both from the pre-heater and the clinker cooler.

Slovakia

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Newest Reference case

Customer Not Disclosable

Heat source: PH and CC gas waste heat recovery ORC electric power: ca. 7 MWeSite: North America

40

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Reference case: Italcementi Group

Client: CIMAR – ITALCEMENTI GROUP (Morocco)


Heat source: PH exhaust gas at 330°C

Cooling: water condenser + air-coolers

No water consumption

ORC electric power: ∼∼∼∼2 MWe

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Air-coolersORC building

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In operation since IV quarter 2010

Working hours: 16.000 h

Availability: >98%

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The plant is being hybridized with CSP (Concentrated Solar Power) taking advantage of the ORC extra capacity:

Reference case: Italcementi Group

By courtesy of Italcementi Group

215 m

11 m

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Total WHRS investment cost• Influenced by many specific project related factors: size, ambient temperature, exhaust gas temperatures and flows, number of heat source, layout, electric connection, water availability, erection cost, etc.

Total installed cost of 3,000 €/kWnet +/-30% can be used as ball park figure

Economical Feasibility is driven mainly by• WHRS investment cost

• Electricity value may range between 0,13 €/kWh (e.g. in Italy with White certificates) to less than 0,05 €/kWh

• Operating hrs: the grater, the better (typical values are 7,500 hrs/annum)

• O&M cost: for complete ORC based plant in the range of 1 % of Capex/year (approximately half of steam based plant)

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First glance at economics

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Heat recovery systems economics

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ORC unit

� ORC module is only a portion of the waste heat recovery system

� Specific investment cost depends on several factors, most importantly the ORC size, but also

specific applications, Client’s requirements and needs, etc.

� According to the size, specific investment ranges from about 700 - 800 € / kW, for units rated

around 5 MW, to more than 1,400 € / kW for units rated less than or equal to 1 MW.

� ORC O&M in the range of 2 – 5 % of Capex / year

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Heat recovery systems economics

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Process heat exchanger, heat carrier loop and balance of plant

Specific investment cost highly affected by project-related and site-related factors, such as• Main process characteristics (continuous or batch)

• Potential multiple heat sources

• Layout constraints

• Climate conditions at the installation site

• Grid connection (voltage, distance)

• Civil works

• …

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Conclusions

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ORC

� allows to take advantage of mid and low-temp. sources from 3 MW to 50 MW

� guarantees high efficiency, reliability and minimum O&M

Turboden

� is European leader in ORC turbogenerators

� has track records in Energy-Intensive Industries, teaming up with specialized

engineering companies and plant makers for specific sectors

…

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Conclusion:Turboden ORC based Waste Heat Recovery

Economic & Technical Feasibility

Automatic, Unmanned Operation Minimal / No impact on cement production processLow operation and maintenance requirements / costNo water consumptionPossibilities of attractive Payback, IRR, and NPV Optimization of the complete solution together with main heat exchangers suppliersTailor made solutions

References in Cement plants

Proven Reliability

Over 250 ORC’s globallyOver 300 MWe installedOver 5 Million hours of operation

turboden orc energy recovery: best practices in energy ...hreii.eu/demo/public/turboden-eeip...

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