Waste Heat Recovery in Energy Intensive Industries 2012 ...

Final Event - Webinar October 6, 2014

Waste Heat Recovery in Energy Intensive Industries

2012-2014 Project Results


Marco Baresi – H-REII DEMO Project Manager

Marco Taesi – Feralpi Group

Simone Castrini – Comeca

Francesco Campana – Turboden

Daniele Forni – FIRE Waste Heat Recovery In Energy Intensive Industries


Partners

Turboden, a Mitsubishi Heavy Industries company, is a global leader in the design, manufacture and

service of Organic Rankine Cycle (ORC) turbogenerators, which harness heat to generate electric and

thermal power from renewable sources (biomass, geothermal, solar energy) and waste heat from

industrial processes, engines and gas turbines. Turboden has about 290 plants in 32 countries and

offers turbogenerators from 200 kWel to 15 MWel.

CO.ME.CA. S.p.A. has been operating in the mechanical structural steel work field for the iron and

steel industry since 1969. Since the very beginning, the company has continuously updated its in-

house machinery, technologies and machining processes to state-of-the-art levels, with the maximum

satisfaction of all its customers in mind. The experience of its highly specialized technical personnel

has made CO.ME.C.A. S.p.A. one of the most qualified and appreciated suppliers in its sector.

FIRE (Italian Federation for Energy Efficiency) is a non-profit organization established in 1988 to

promote the efficient use of energy. Since 1992 FIRE manages the Italian energy manager network

on behalf of the Ministry of Economic Development, promoting their role through various initiatives.

FIRE also encourages in collaboration with the relevant institutions a positive development of the

legislative and regulatory framework in order to foster an efficient use of energy.

Agenda

Why the H-REII Demo

Technical aspects

the overall concept

the heat exchanger

the ORC

Policy, regulatory aspects and dissemination

Agenda

Why the H-REII Demo

Marco Baresi - HREII-DEMO Project Manager

Technical aspects

the overall concept

the heat exchanger

the ORC


Heat Recovery in Energy Intensive Industries

… the policy project !

quantify the potential heat recovery for electricity

generation in the Italian EIIs (pilot model)

energy audits in EIIs: 49 in Italy, 50 in Austria

promote energy efficiency policy in Italy

training and dissemination

Turboden technology

CSMT scientific

FIRE scientific

Confindustria institutional

Provincia di Brescia institutional

H-REII experience 2010-2012

Heat Recovery in Energy Intensive Industries

… the demonstration project !

support demonstration of ORC heat recovery plant in

the Steel Industry

quantify the potential in the European EIIs

promote energy efficiency policy in Europe

(disseminating best practice)

training and dissemination

Turboden technology

Comeca technology

FIRE scientific

H-REII became DEMO 2012-2014

Waste Heat Recovery

Electric Arc Furnace

(EAF)

Heat exchangers

+ Steam drum

Industrial thermal user

Exhaust gases

Organic Rankine

Cycle

Electric energy

Reducing consumption

World first

demonstrative plant

at ESF Feralpi

Riesa, Germany

in operation since

Dec. 2013

Agenda

Why the H-REII Demo

Technical aspects

the overall concept

Marco Taesi – Feralpi Group

the heat exchanger

the ORC


Elbe Stahlwerke Feralpi Riesa, Germany

The Group has 1,300 employees in Italy and other EU countries. Present in Germany since 1992

(with ESF Elbe-Stahlwerke Feralpi GmbH in Riesa), also operates in the Czech Republic and

Hungary.

Feralpi continues pursue investment programs aimed at technological innovation and boosting

production efficiency, a means to minimize costs and increase its competitive edge.

The Feralpi Group was founded in

1968 and is recognized as a leading

European manufacturer of iron and

steel, especially steels for the building

industry. In 2013, the Group achieved

a consolidated turnover of € 944 mln,

and turned out:

1.9 million tonnes of steel in billets,

1.7 mln ton of finished products and

0.57 mln ton of cold-rolled products.

Elbe Stahlwerke Feralpi Germany: Product and technology

ESF Elbe-Stahlwerke Feralpi GmbH produces reinforcing steel in the form of bars and coils

Steel shop for steel billets as semi-finished product (up to 1 million tons of steel billets)

Hot rolling mill (up to 0.8 million tons of reinforcing steel per year)

In Riesa the steel production activity has a long tradition: since 1843.

From 2012 ESF has been certified with EMAS (Eco Management and Audit Scheme).

Drivers to project development

The companies in the Feralpi Group collaborate with independent agencies on several scientific

research projects.

Most of the programs cover several years and, due to their importance, Feralpi benefits from

European and domestic public grants, and is considered a benchmark for best practice in a

number of areas, such as de-dusting technology, reducing CO2 emissions and effective

management of the electric furnace charge mix.

Of particular interest is the HREII-Demo project, which was launched in Riesa in 2012 and has

developed a highly innovative technology to recover steam from the mill’s electric furnace, which

would otherwise be dispersed into the atmosphere in the form of water vapor.

H-REII Demo – the plant

Heat to power system Industrial heat recovery source

Power

Cooling system

Heat carrier loop Saturated steam

Thermal user

Local Municipality

http://www.tenova-reenergy.com/de/home.html

Steam and condensate return pipeline

Distance between steel shop and thermal user: 0.8 miles

ESF: Waste Heat to Power layout

0

ORC Unit

Steel Shop

0

Thermal user: tire plant

Waste Heat Boiler

Evaporative Cooling System

Local Municipality


Steam and condensate return pipeline

Distance between steel shop and thermal user: 0.8 miles

ESF: Waste Heat to Power layout

0

ORC Unit

Steel Shop

0

Thermal user: tire plant

Waste Heat Boiler

Evaporative Cooling System

Local Municipality

Project Focus


Agenda

Why the H-REII Demo

Technical aspects

the overall concept

the heat exchanger

Simone Castrini– Comeca

the ORC


EAF

Heat Exchangers

Thermal user ORC

Thermal users

Electricity

Water cooling

Electricity + Fossil Fuels

+ Metal Oxidation

Electric Arc

Furnaces

Metal Scrap Melting

Fumes

ORC

Losses

Radiation

Heat

Exchanger

Steam

Steam

accumulator

Fumes

Steam

Fumes

Baghouse

Filter

Steam

Convective

Heat

Exchanger

Stack

Steam

EAF Heat Recovery: Heat exchangers

Typical EAF Cooling System

H-REII Demo – Technical detail


Evaporative Cooling System – Reference plant Georgsmarienhütte GmbH



Tenova Evaporative Cooling System Comeca Waste Heat Recovery (Co-designed with Tenova) + Turboden ORC


Tenova Evaporative Cooling System Comeca Waste Heat Recovery (Co-designed with Tenova) + Turboden ORC

innovation

EAF

Heat Exchangers

Thermal user ORC


1. Radiation heat exchanger 2. Convective heat exchanger

3. Steam drum 4. Steam accumulator Courtesy of


EAF

Heat Exchangers

Thermal user ORC


1. Radiation heat exchanger 2. Convective heat exchanger

3. Steam drum 4. Steam accumulator Courtesy of

Project Focus


EAF

Heat Exchangers

Thermal user ORC

EAF Heat Recovery: Waste Heat Boiler

Overview of Waste Heat Boiler LIFE+ logo

EAF

Heat Exchangers

Thermal user ORC

Fumes flow rate range 100,000 – 140,000 Nm3/h

Fumes inlet temperature ≈ 600°C

Fumes outlet temperature ≈ 220°C

Average steam flow rate 20 t/h

Average steam temperature 245°C

Average steam pressure 27 bar(a)

EAF Heat Recovery: Waste Heat Boiler

Agenda

Why the H-REII Demo

Technical aspects

the overall concept

the heat exchanger

the ORC

Francesco Campana – Turboden


power

heat

Biomass

Waste-heat

Geothermal

Solar

Turboden designs and develops ORC turbines for the combined generation of heat and electric power from various sources, particularly suitable for distributed generation.

Organic Rankine Cycle turbogenerators

Sizes range: from 200 kW to 15 MW on a single turbine*

* Larger systems can be obtained trough modular design

Heat recovery through Turboden ORC

heat

Project Focus

ORC thermodynamics

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 (834). The organic fluid vapor

powers the turbine (45), which is directly coupled to the electric generator through an elastic

coupling. The exhaust vapor flows through the regenerator (59) where it heats the organic

liquid (28). The vapor is then condensed in the condenser (cooled by the water flow or other)

(961). The organic fluid liquid is finally pumped (12) to the regenerator and then to the

evaporator, thus completing the sequence of operations in the closed-loop circuit.

Turbine

Generator

Pre-heater

Cooling medium

Condenser

Evaporator

Pump

Heat carrier

Electric energy

Tem

pe

ratu

re

Entropy

ORC compared to steam

Steam Rankine Cycle

Tem

per

atu

re

Entropy

Tem

per

atu

re

Entropy

Organic Rankine Cycle (ORC)

• High enthalpy drop • Superheating needed • Risk of blade erosion

• Small enthalpy drop • No need to superheat • No risk of blade erosion

Thermodynamic features and

consequences

• Water treatment required • Specialized personnel needed • High pressures and temperatures

• Non oxidizing working fluid • Minimum personnel and O&M(1)

• Automatic/self regulation(2)

Operation and maintenance costs

• Convenient for plants > 10 MW • Low flexibility • Lower performances at partial load

• High flexibility and good performances at partial load

• Well proven in industrial heat recovery

Other features

(1) Standard maintenance: 2-3 days per year (2) Fast start-stop procedure (ca. 20 min), partial load operation (down to 10% of nominal load)

EAF

Heat Exchangers

Thermal user ORC

Design point hot source mass flow 20 t/h saturated steam

Inlet temperature to ORC range 228÷245°C

Design inlet pressure to ORC 27 bar(a)

Design inlet thermal power to the ORC 13,517 kWth

Condensate outlet temperature from ORC 100°C

Cooling water temperatures (in/out ORC) 26/44°C

Thermal power to the cooling water 10,640 kWth

Gross electric power output guaranteed 2,680 kWe

Net electric power output 2,560 kWe

H-REII Demo: ORC power unit

31

EAF

Heat Exchangers

Thermal user ORC

Turboden unit installation phase


Turboden unit installed

EAF

Heat Exchangers

Thermal user ORC


Project timeline

Sep. 2014

H-REII Demo

conclusion

Jan. 2012:

H-REII Demo

Kick off

2012

Feb. – May 2013:

Components

delivered at ESF

waiting for EAF

annual

maintenance

shutdown

2012:

Components design,

manufacturing and

assembly

2013

Aug. 2013:

- heat

exchanger

installed

- ORC cold test

2014

Dec. 18, 2013

ORC first parallel

Dec. 19, 2013

nominal power

(2.6 MW) achieved

Mar. 2014:

Test on site

completed

Jun. – Sep. 2014:

Analysis of

performance data

collection

Performance Analysis

0

500

1.000

1.500

2.000

2.500

3.000

August 5, 2014 - Gross ORC Power output [kW]

Example of 12 hours operating at nominal load

Performance Analysis

0

10

20

30

40

50

60

70

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

August 2014 - ORC daily energy output [MWh]

Agenda

Why the H-REII Demo

Technical aspects

the overall concept

the heat exchanger

the ORC


Daniele Forni – FIRE

Regulatory framework

A paper collecting incentive schemes and legislations across several EU Member States has been released. It provides an analysis of policies or preparative studies to support electricity generation from waste heat recovery. In particular data were collected regarding: • Belgium (Wallon Region) • France • Germany • Italy • Norway • Poland • Spain • Sweden • Netherlands • United Kingdom

And heat mapping georeferenced tools in Germany, Netherlands and UK.

Waste heat recovery potential in EU with ORC technology

Deliverable 07a: Contribution to the EU Energy Efficiency Action Plan

Process

Heat source T [°C]

PsORC [kW/t]

Plants

ORC

power [MW]

Flat Glass 500 2.33 58 79

Clinker Prod.

350 1.01 241 574

EAF 250 27.8 190 438

Rolling mills

400 6.87 209 310

GCS 30% 500 1 155

Total 2 556

ORC potential in EU Energy Intensive Industries

Sectors

Energy recovery [GWh/yr]

Emission avoided [103t CO2/yr]

5000h 8000h 5000h 8000h

Flat Glass 393 628 140 225

Cement 2 870 4 592 1 213 1 940

Steel 3 740 5 984 1 351 2 162

GCS 5 775 9 240 2 062 3 299

EU 27 12 778 20 444 4 766 7 626

Energy generated from WHR and CO2 emissions saving in EU27 industries

Annual energy recovery in EU27 industries

2.5 GW ORC potential in EII

20 TWh of electric energy

7.5 million tonnes CO2 emissions avoided

Published on October 25, 2012, entered into force on December 4, 2012 Transposed by Member States in summer 2014

Article Article content

Art 7 Energy efficiency obligation

schemes

Energy savings must be equal to 1.5% per year in the period 2014-2020 Financial schemes and instruments or fiscal incentives

Art 8 Energy audits and energy

management systems

Obligation of energy audit every 4 years for non-SMEs

Art 14 Promotion of efficiency in

heating and cooling

Assessment of the potential for the application of high-efficiency cogeneration and efficient district heating and cooling by December 31, 2015 Cost-benefit analysis for the refurbishment of plants > 20 MW of thermal input

Art 15 Energy transformation,

transmission and distribution

Assessment of energy efficiency potential of MS gas and electricity infrastructures MS shall ensure the removal of incentives and distribution tariffs detrimental to the overall efficiency of the generation, transmission, distribution and supply of electricity

Art. 20 Energy Efficiency National

Fund

MS may set up Energy Efficiency National Fund

Waste Heat Recovery has a relevant role in the EED and there are several provisions of interest for waste heat to energy systems

EU Energy Efficiency Directive (2012/27/EU)


Relevant studies developed Studies Expected benefits from WHR through ORC technology

November 2012

Waste heat to energy to increase industrial competitiveness

AGICI - International Observatory for Renewables June 2013

Industrial policy instrument for relaunching the Italian industry

Smart Energy Project October 2013

1.7 billion € in 17 years the country system net benefit with 50% penetration on potential waste heat recovery in E.I.I. in Italy Industrial policy – competitiveness, sustainability, job creation

Sector Marginality variation

Chemical +2%

Products for building +12%

Steel +5%

Glass +11%


Estimated potential for heat to energy recovery from UK industries: 1 TWh/yr

Relevance of H-REII project results in the ADEME analysis on existing policies in WHR at global level

Deliverable 07b: Contribution to the National Energy Efficiency Action Plan

Studies in France and UK

The Energy Efficiency Industrial Platform (EEIP)

• EEIP is a platform for Business and Policy in Europe, it facilitates dialogue within industry and between industry and policy • Strong involvement of H-REII DEMO in the EEIP work on industrial

heat recovery and financing of energy efficiency

www.ee-ip.org

http://www.ee-ip.org



Dissemination Activity

more than 13,000 website visits 100 events attended articles and papers Layman Report

www.hreii.eu/demo

ECOS 2014

http://www.hreei.eu/demo


Marco Baresi – [email protected]

Marco Taesi – [email protected]

Simone Castrini – [email protected]

Francesco Campana – [email protected]

Daniele Forni – [email protected]

Waste Heat Recovery In Energy Intensive Industries


Waste Heat Recovery in Energy Intensive Industries 2012 ...

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