Turn waste heat into value: the dependable Turboden ORC solutions Global Cement Waste Heat Recovery Conference and Exhibition City of London - Thursday 14 th - Friday 15 th June 2012 Codice doc. 12-A-347-rev.0
Turn waste heat into value:
the dependable Turboden ORC solutions
Global Cement Waste Heat Recovery Conference and
Exhibition
City of London - Thursday 14th - Friday 15th June 2012
Codice doc. 12-A-347-rev.0
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Agenda
• Company introduction
• ORC based heat recovery plants: main features
• Some reference cases in cement
• Other heat recovery fields
• HREII DEMO: an introduction
• Turboden / PWPS deployment
• Conclusion
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Turboden is a leading European company in development and production
of ORC (Organic Rankine Cycle) turbogenerators. This state of the art
equipment generates heat and power from renewable sources and heat
recovery in industrial processes.
The company was founded in 1980 in Milan by Eng. Mario Gaia, former
Professor of Energy at the Polytechnic of Milan, and today the Managing
Director of Turboden. His close connection with the university has always
ensured the recruitment of highly qualified R&D personnel.
Turboden has always had a single mission: design ORC turbogenerators
for the production of heat and electrical power from renewable sources, while
constantly striving to implement ORC technical solutions.
In 2009, Turboden became part of Pratt & Whitney (UTC Corp.), a
worldwide leader in development, production and service for aero engines,
aerospace drive systems and heavy duty gas turbines.
Today Turboden is part of Pratt & Whitney Power Systems (PWPS), to
develop ORC solutions from renewable sources and waste heat worldwide.
Company Introduction
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United Technologies Corporation
4
Research
Center
Hamilton
Sundstrand
Sikorsky UTC Power Otis Carrier UTC
Fire & Security
Large
Engines After
market Marine
Mobile
Power
Fortune 50 corporation
16th largest US manufacturer
$54.3B in 2010 sales
195 countries
210,000 employees
Wind
Power
EPC
Service
ORC
Technology
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standard units from 600 kW to 6 MW
customized solutions up to 15 MW
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electricity
heat
Biomass
Waste-heat
Geothermal
Solar
What We Do
Turboden designs and develops turbogenerators based on the Organic
Rankine Cycle (ORC), a technology for the combined generation of
heat and electrical power from various renewable sources, particularly
suitable for distributed generation.
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ORC based heat recovery plants
The Thermodynamic Principle of ORC Cycle
The turbogenerator uses the 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) (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.
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ORC based heat recovery plants:
Integration scheme to Cement Plant
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ORC based heat recovery plants:
Main advantages
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Presence of an intermediate loop (thermal oil or pressurised water)
• ease of control and operation, even when big fluctuations in primary heat sources
• great layout flexibility
automated and unmanned systems
High molecular weight of organic working fluid • low enthalpy drop across the turbine
• low turbine peripheral speed (low mechanical stress and no reduction gear)
• reduced number of turbine stages
• high mass flow
turbine efficiency > 80 %, good part load efficiencies
No corrosion attitudes of working fluids
long life of the system and low maintenance requirements
Zero Water consumption configuration (option) • no water management activities (pH and salts control, water refilling)
• no water needed
low operation requirements, no water depletion
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Heat Recovery In Cement Production Process
Reference Case study: PRS gas waste heat recovery
Clinker production capacity: ≈ 5.000 ton/day
Heat source: exhaust gas @ 330°C
Gas cooled down to 220°C (extra heat used for raw
material pre heating)
ORC electric power: ca. 2 MWe
Client: CIMAR – ITALCEMENTI GROUP (Morocco)
In operation since IV quarter 2010
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Heat Recovery In Cement Production Process
Project Holcim Romania
Reference Case study: PRS and CC gas waste heat recovery
Clinker production capacity: ≈ 4.000 ton/day
Heat source: exhaust gas @ 360°C (PRS) and hot air @ 250 °C (CC)
Thermal oil (PRS) and pressurised water (CC) heat recovery loops
ORC electric power: ca. 4 MWe
Client: Holcim Romania – Holcim Group (Romania)
Under Construction; start up expected in June 2012
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Romania
ORC plant PH boiler AQCboiler
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Heat Recovery In Cement Production Process
Project Holcim Slovakia
Reference Case study: PRS and CC gas waste heat recovery
Clinker production capacity: ≈ 3.600 ton/day
Heat source: exhaust gas @ 360°C (PRS) and hot air @ 310 °C (CC)
Thermal oil heat recovery loops
ORC electric power: ca. 5 MWe
Client: Holcim Slovakia – Holcim Group (Slovakia)
Under Construction; start up expected in II quarter 2013
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Slovakia
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ORC based heat recovery plants:
A first sight to economics
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Total WHRS 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, etc.
Total installed cost of 3,000 €/kWnet +/-30% can be used as ball park figure
Financial results are driven by few main factors • WHRS cost
• Electricity value may range between 0,13 €/kWh (e.g. in Italy with White certificates) to
less than 0,05 €
• Operating hrs: the grater, the better (typical values are 7,500 hrs/annum)
• O&M cost: for ORC based plant it’s in the range of 1 % of Capex/year (indicatively half
of steam based plant)
Some examples:
Scenario Best Medium Worst
Capex [€/kW] 2500 3500 4500
Opex [€/kW/y] 35 35 35
Operating hrs 7800 7500 7000
Energy value [€/kWh] 0,12 0,08 0,06
WACC 7% 10% 13%
PBT 3,2 8,7 > 15 yrs
IRR @ 20 year 36% 15% 6%
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GOALs:
a) To realize an integrated fumes depuration and heat recovery system
b) To develop policy and governance actions for reducing CO2
emissions by valorisation of process effluents in Energy Intensive
Industries
For more information: www.hreii.eu/demo
H-REII DEMO Project
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ORC
200 - 900 °C
150 - 350 °C
300 - 1600 °C
Target:
3-5% of the
EAF
installed
power
25%
30% of the
power inserted in the
furnace is lost in the
exhaust
70% of the lost power
could be recovered
Heat recovery from Electric Arc Furnace
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PROJECT IN A GERMAN IRON&STEEL FACTORY
Exhaust gas from EAF (100 t) with steam production
Primary heat source: exhaust gas from EAF
Steam production:
The steam is produced from two different heat sources:
1. Pipe to pipe duct, modified to work with pressurized water at the
boiling point
2. Substitution of the quenching tower with a shell and tubes heat
exchanger which produces steam.
Steam produced: ~ 30 t/h of steam at 27 bar - 245°C
Steam available for the ORC unit:
~ 20 t/h of steam at 27 bar and 245°C (10 t/h is delivered to an industrial process)
Gross power output ORC unit: ~ 3 Mwe
High flexibility of the heat recovery system: the ORC properly operates with a steam flow rate
between 2 and 22 t/h, automatically adapting its operation to the different operating conditions
THE SYSTEM AUTOMATICALLY FOLLOWS THE EAF MELTING CYCLE
Heat recovery from Electric Arc Furnace
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EU MSs considered in the analysis: Italy, Germany, France, Spain, UK and Belgium ( 95% of European production in the three areas examined ) + Austria, Czech Rep.
HREII Demo project: first EU estimates
Power to recovery in Europe (first estimation):
630 MWe from 3,2 TWh/y to 5 TWh/y
Steel: 376,6
Cement: 145,8 Glass: 107,1
Total: 629,5
0
100
200
300
400
500
600
700
po
we
r M
W
Sectors
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Heat Recovery In Glass Production Process
Reference Case study: Float glass production process
Glass production capacity: ≈ 600 ton/day
Heat source: exhaust gas at approximately 500°C
ORC electric power: ca. 1,3 MWe
Final Client: AGC Glass Europe – Cuneo Plant
General contractor: GEA Bischoff
In operation since I quarter 2012
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Heat Recovery In Refractory Production Process
Reference Case study: Refractory ovens exhaust
gas heat recovery
Refractory production capacity: ≈ 250 ton/day
Heat source: exhaust gas @ 500 °C
Gas cooled down to ca. 150 °C
ORC electric power: ca. 1 MWe
Client: RHI GROUP (Radenthein - Austria)
In operation since I quarter 2009
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Heat Recovery from Waste Incineration plant
Plant type:
Heat recovery from pressurized
water boiler in waste incinerator
Customer :
MIROM (Roeselare-Belgium)
In operation since:
II quarter 2008
Heat source:
hot water at 180
C (back 140
C)
Cooling source:
water/air
Total electric power:
3 MWel
Net electric efficiency: 16,5%
Availability: > 98%
Example of Turboden tailor-made ORC plant for heat
recovery from hot water: 3 MWe installation in Roeselare (B)
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Turboden strong points
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• Participation in national
& EU research
programs
• Cooperation with EU
Universities and
Research Centres
• Thermodynamic cycle
optimization
• Working fluid selection
& testing
• Thermo-fluid-dynamic
design and validation
• Implementation & testing
of control/ supervision
software
• Many patents obtained
• Pre-feasibility
studies: evaluation of
technical &
economical
feasibility of ORC
power plants
• Customized
proposals to
maximize economic
& environmental
targets
• Complete in-house
mechanical design
• Proprietary design
and own
manufacturing of
ORC optimized
turbine
• Tools
- Thermo-fluid-
dynamic programs
- FEA
- 3D CAD-CAM
- Vibration analysis
• Start-up and
commissioning
• Maintenance,
technical assistance
to operation and
spare parts service
• Remote monitoring
& optimization of
plant operation
• Outsourced
components from
highly qualified
suppliers
• Quality assurance &
project management
• In house skid
mounting to
minimize site
activities
R&D Sales/marketing Design Operations &
manufacturing Aftermarket
service
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Turboden – facts & figures
(Last update: February 2012) 22
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Conclusions
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Turboden & PWPS ORC based WHRS for cement • Ease of integration into existing plants
• Very low O&M costs
• Automatic and unmanned operations
• Profitable plants
Optimum solution for industrial users minimising any effect on primary
process
Turboden & PWPS • Have real experience in WHRS in Energy Intensive Industries (Cement, Steel, Glass)
• Can provide customised solutions to meet customers requests
• Have established a network with major stakeholders (WHR exchangers makers, WHR
plant integrators, financing companies and record access to European funds)
The dependable technological partner to successfully exploit WHR
Turboden s.r.l.
Via Cernaia, 10 - 25124 Brescia, Italia
tel +390303552001 - fax +390303552011
[email protected] www.turboden.it
C.F./P.I. IT02582620981
capitale sociale €1.800.000 i.v.
R.I.: C.C.I.A.A. di Brescia 02582620981
REA 461817
Thank you
For more information:
Riccardo Vescovo
Sales Manager Heat Recovery Department