Nicolas Bernier, 5 ft June 2018 Waste Heat Recovery using Organic Rankine Cycle turbines The content of this document is the exclusive property of Sustenea and cannot be revealed, used or reproduced without the written authorization of Sustenea
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Nicolas Bernier, 5ft June 2018
Waste Heat Recoveryusing
Organic Rankine Cycle turbines
The content of this document is the exclusive property of Sustenea and cannot be revealed, used or reproduced without the written authorization of Sustenea
River and Marine hydrokinetic turbinesIndustrial waste heat : the example of France (1)
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Waste Heat Recovery using ORC turbines
Source : ADEME (2014)
drying
Fuel100 %
Heat balance , fuel furnace, permanent regime
Fumes loss25 to 60 %
Loss due to openings3 to 10 %
Loss due to walls3 to 10 %
Loss due to conveyors3 to 10 %
Useful heat100 %
River and Marine hydrokinetic turbinesIndustrial waste heat : the example of France (2)
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Waste Heat Recovery using ORC turbines
Source : ADEME (2014)
drying
Typically : agro, paper, chemical industry Typically : steel mill, cement & glass factories
Liq
uid
dis
char
geG
aseo
us
dis
char
geD
iffu
se d
isch
arge
River and Marine hydrokinetic turbinesIndustrial waste heat : the example of France (3)
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Waste Heat Recovery using ORC turbines
Source : ADEME (2014)
drying
Fuel consumption
Useful heatfor production
Waste heat definitely lost
Wasteheat
- Heating networks- Electricity production
Energy efficiency actions on site
Recoverablewasteheat
Waste heat avoided
Waste heat recovered
on site
Waste heat recovered
and exported
River and Marine hydrokinetic turbinesIndustrial waste heat : the example of France (4)
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Waste Heat Recovery using ORC turbines
Source : ADEME (2014)
drying
Figures in brief319 TWh : 275 TWh (industry)
44 TWh (refineries)
process : furnaces, dryer, boilers
temperature > 100°C fumes, vaporized fluids
Industrialwaste heat
>100°C51 TWh
Losses frombiolers’ fumes
Remaining heatfrom dryers
Losses fromfurnaces’ fumes
Industrialwaste heat
>100°C51 TWh
3 x 8 hno weekend
stops
3 x 8 hwith
weekend stops
non metal materials
chemistryplastics
refineries
agro-industry
steel andother metals
papercardboard
others
River and Marine hydrokinetic turbinesIndustrial waste heat : the example of France (5)
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Waste Heat Recovery using ORC turbines
Source : ADEME (2014)
drying
1,1 TWh250 sites1,400 MWe potential
Fuel consumption Waste heat Gross power production
Net power production
River and Marine hydrokinetic turbinesIndustrial Waste Heat Recovery
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Waste Heat Recovery using ORC turbines
Purchased fuels(oil, gas, biomass, etc.)
Heat generation(boilers, fired heaters/furnaces, etc.)
Process
Cooling system(cooling towers, closed loop cooling, etc.)
Surroundings(rivers, air, etc.)
Electricity generated(engine, ST, ORC, etc.)
Genset
Electricity purchased(oil, gas, biomass, etc.)
ORC
ST, ORC
Electricity
Genset
Heat
Cold
River and Marine hydrokinetic turbinesOrganic Rankine Cycle
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Waste Heat Recovery using ORC turbines
Expanding heat to power scope of possibilities
▻ no fuel ▻ no chemicals*▻ no combustion ▻ no need for high pressure▻ no emissions ▻ suitable with temperatures as low as 80°C
* hot loop
River and Marine hydrokinetic turbinesWHR using ORC technology in the world
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Waste Heat Recovery using ORC turbines
In operations for 35 years, producing more than 3,000 MW worldwide!
More players since the years 2000
Source : orc-world-map.org (2015)
River and Marine hydrokinetic turbinesWHR using ORC technology : types of activities
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Waste Heat Recovery using ORC turbines
Source : orc-world-map.org (2015)
River and Marine hydrokinetic turbinesReminder of Organic Rankine Cycle (ORC) technology
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Waste Heat Recovery using ORC turbines
- thermal oil- superheated water- (hot gas)
Cold Loop
ORC Turbine
Con
den
ser
Generator
Evap
orat
or
Working fluid vaporized(vapor phase)
Working fluid condensed(liquid phase)
Organic Fluid Loop
Heat exchanger
Wet coolers
Dry coolers
Pump
Waste heatCooling
Hot loop
- water
River and Marine hydrokinetic turbinesFigures for a very low enthalpy waste heat recovery
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbinesComparative table between ST and ORC solutions (1)
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Waste Heat Recovery using ORC turbines
Steam turbines ORC turbines
Hot loop
fluid purified water steam thermal oil or superheated water
pressure 20 to 300 bar 5-20 bar
temperature 250-550°C 80-330°C
chemicals yes (water purification) no
reheating device yes (water purification) no
Working fluid loop
fluid dry purified water steam (HP) « organic » fluid
possible droplets at LP stages
water consumption yes no
pressure inlet turbine 20 to 300 bar 5-20 bar
temperature inlet turbine 250-550°C 80-330°C
pressure oulet turbine < 2 bar
temperature outlet turbines 100-45°C ~60°C
CHP possible possible
Turbine
blades up to tens of stages 1 to ~15
diameter up to several meters 10 to 60 cm
rotation speed 1800-3600 rpm up to 1800 rpm
River and Marine hydrokinetic turbinesComparative table between ST and ORC solutions (2)
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Waste Heat Recovery using ORC turbines
ST ORC
Availability 80-90% 98%
Load variation -5/+5% -60/+120
Pressure, temperature High Low
Corrosion (efficiency decrease) Yes No
Lifetime 15 20-25
Water consumption, chemicals Yes No
Maintenance, OPEX High Low
ORC versus steam turbines technologies
ST ORC
CAPEX + -
Installation and commissioning - +
Exploitation, availability (incomes) - +
Maintenance, OPEX - +
Value and options at the end of the PPA - +
Overall benefits at the end of the PPA - +
Financial benefits choosing ORC tech.
River and Marine hydrokinetic turbinesSteam and ORC turbines
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Waste Heat Recovery using ORC turbines
ORC turbine
Turbo expander: combination of a micro turbine with an integrated generator
Potential applications are not only ORC but also C02 cycle, natural gas expansion, process gas expansion, hot air energy recovery
Steam turbine
HP stages
LP stages
River and Marine hydrokinetic turbinesVarious ORC applications
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Waste Heat Recovery using ORC turbines
Transportation
↪ Vessels
↪ Railroad
↪ Heavy Duty Trucks
Biomass
↪ Biomass to electricity
↪ Biomass CHP
↪ Isolated site
Biogas, landfill gas
↪ Enhancement of biogas engine via exhaust, water jacket or both
↪ Direct biogas to electricity conversion with boiler
Industrial Waste Heat Recovery
↪ Process Heat
↪ Exhaust gases
↪ Waste steam
Geothermal
↪ Natural hot sources
↪ Medium temperature
wells (from 80°C)
Diesel and gas gensets↪ Efficiency enhancement via exhaust, water jacket or both
Solar
↪ Solar CHP with CSP field
↪ Solar CHP with CSP and heat storage
Education and research
↪ With boiler simulating heat source
Renewable Energies
Energy Efficiency
River and Marine hydrokinetic turbinesIndustrial waste heat recovery
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Waste Heat Recovery using ORC turbines
▻ cement factories▻ still mills▻ foundries▻ glass furnaces▻ refineries▻ aluminium smelters▻ incinerators▻ plants treating sewage through incineration▻ paper factories▻ agro-industry▻ etc.
● fumes● industrial process● excess steam
River and Marine hydrokinetic turbinesCase study : cement factory (1)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbinesCase study : cement factory (2)
The content of this document is the exclusive property of Sustenea and cannot be revealed, used or reproduced without the written authorization of Sustenea
Waste Heat Recovery using ORC turbines
Scope / Investment
2x ATM-3000H (2 x ORC 3000 kWe)
Estimated CAPEX for turnkey PP : 20 MUSDIncentives : 0Annual OPEX : 0.5 MUSD
Performance
Net production : 5742 kWeORC availability : 8500 h (97 %)Global availability : 8000 h (91%)Annual production : 45.936 GWh
Profitability
TRI (80 USD/MWh): 6 years TRI (100 USD/MWh): 5 years LCOE (10 years) : 54 USD/MWh LCOE (20 years) : 32 USD/MWh
y0 y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 y11 y12 y13 y14 y15 y16 y17 y18 y19 y20
-20.0
-10.0
0.0
10.0
20.0
30.0
40.0
50.0
60.0
Electricity tariff of 80 USD/MWh
River and Marine hydrokinetic turbinesCase study : WHR from biomass dryer (1)
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Waste Heat Recovery using ORC turbines
Charcoal and pelets factory: recovering excess heat from the dryer
Turbine
200 kW Electricity Production
Hot water loop30 kg/s
110°C
ORC (Scope of the pre-quotation)
Pump
Evaporator
Condenser
50°C
Cold water19 kg/s
130°C
Heat exchanger
2,5 MW recovered thermal power
200°C Hot air
30°C
River and Marine hydrokinetic turbinesCase study : WHR from biomass dryer (1)
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Waste Heat Recovery using ORC turbines
Scope / Investment
1x ENO-200LT (ORC 200 kWe)
Estimated global CAPEX : 600 kUSDIncentives : 0Annual OPEX : 15 kUSD
Performance
Net production : 180 kWeORC availability : 8670 h (99 %)Global availability : 8500 h (97%)Annual production : 1,530 MWh
Profitability
TRI (100 USD/MWh): 4- years LCOE (10 years) : 92,5 USD/MWh
y0 y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 y11 y12 y13 y14 y15 y16 y17 y18 y19 y20
-1,000
-500
0
500
1,000
1,500
2,000
2,500
Electricity tariff of 0.1 USD/kWh
River and Marine hydrokinetic turbinesInternal Combustion Engines (ICE) heat recovery
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Waste Heat Recovery using ORC turbines
● Diesel, HFO, gas, biogas● Exhaust gases and possibly jacket water heat the thermal oil with a heat exchanger● Approximately 10% additional electricity is produced
River and Marine hydrokinetic turbinesCase study : WHR from a biogas engine
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Waste Heat Recovery using ORC turbines
With a Jenbacher biogas engine
River and Marine hydrokinetic turbinesGas flaring
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Waste Heat Recovery using ORC turbines
● ORC technology provides a solution to reduce flaring and venting● Low quality gases from well are diverted to a boiler (Thermal Oil Heater).
River and Marine hydrokinetic turbinesCase study: oil wells conversion –> geothermal (1)
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Waste Heat Recovery using ORC turbines
Turbine
Electricity Production
Hot water110°C
19 kg/s
90°C
Ambient temperature : 31°C
Cooling systemORC (Scope of the pre-quotation)
Pump
Evaporator
Condenser
50°C
40°C
The estimated recoverable :- heat output is 1580 kWth
- net power output is 88 kWe
1580 kW th
98 kWe
88 kWe
River and Marine hydrokinetic turbinesCase study: oil wells conversion –> geothermal (2)
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Waste Heat Recovery using ORC turbines
Scope / Investment
ENO-100LT (ORC 100 kWe)
Estimated global CAPEX : 350 kUSDIncentives : 0OPEX : 30 kUSD
Performance
Gross production : 98 kWeNet production : 88 kWeORC availability : 8670 h (99 %)Global availability : 8500 h (97%)Annual production : 748 MWh
y 0
y 2
y 4
y 6
y 8
y 10
y 12
y 14
y 16
y 18
y 20
-400
-200
0
200
400
600
800
y 0
y 2
y 4
y 6
y 8
y 10
y 12
y 14
y 16
y 18
y 20
-500
500
1,000
1,500
2,000
2,500
Profitability
TRI (100 USD/MWh): 6+ yearsTRI (200 USD/MWh): 3- yearsLCOE (10 years) : 87 USD/MWhLCOE (20 years) : 63,5 USD/MWh
Electricity tariff of 0.1 USD/kWh
Electricity tariff of 0.2 USD/kWh
River and Marine hydrokinetic turbinesCase study: oil wells conversion – geothermal (3)
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Waste Heat Recovery using ORC turbines
Ambient temperature : 31°C
Mass flow rate – kg/s
Ele
ctric
ity p
rod
uct
ion
– k
W
Estimate of electricity production for various flow rates and temperatures of the source
River and Marine hydrokinetic turbinesShip’s diesel engine heat recovery (1)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbinesShip’s diesel engine heat recovery (2)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbinesOcean Thermal Energy Conversion (OTEC)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbinesContact details
Nicolas [email protected] +62 899 4749 259
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Thank you for your attention!
Waste Heat Recovery using ORC turbines
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