Marc van wonterghem | E-Rational - value for heat

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Bezoek aan Proviron (Raf Jacxsens/ Marc Van Wonterghem van E-rational)

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E-RATIONAL is a BEP Europe division

E-RATIONAL | Ten Briele 6 | 8200 Brugge | Belgium | T +32 50 40 85 40 | F +32 50 38 01 60 | www.e-rational.net

Turning waste heat

into

Clean Energy

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BURKE E PORTER | Global Organization

BEP Europe employs over 100 people

7,500 square meter manufacturing area capable of

fabrication, machining and final assembly.

Burke E Porter, the corporate headquarters,

employs over 100 people

9,750 square meter manufacturing area capable of

fabrication, machining and final assembly.

BEP Wuxi employs over 75 people

3,700 square meter manufacturing area capable of

fabrication, machining and final assembly.

Burke E Porter, ww employs over 450 people

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Turnover in US$ Sales in USD

BURKE E PORTER | Turnover History

BEP in numbers…

Fiscal year ends on March 31

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Overview

BEP Europe | Products

End-of-Line Production Test Systems for :

Wheel alignment (toe, camber, caster)

Headlight Aiming

Roll & Brake

Rattle & Twist

Driver Assistance

Powertrain & drivetrain

Wheel & Tire Assembly Systems

Vision Systems, Machine Control & Data Acquisition Systems

Dynamometers

Chassis Dynamometers

Emission Testing, Mileage Accumulation, Climatic/Wind Tunnel, Noise, Vibration and Harshness, Research & Development

Powertrain Dynamometers

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BEP Europe | Products

Roll & Break

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BURKE E PORTER | Some of our customers

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Germany

Audi - Ingolstadt,

Neckarsulm

Daimler/Chrysler –

Bremen

Opel – Eisenach,

Rüsselsheim

Volkswagen – Emden,

Wolfsburg, Hannover,

Mosel…

Great Brittan

IBC – Luton

Jaguar – Castle

Bromwich

Ford -

Southampton

France

PSA – Aulnay, Mulhouse,

Rennes, Sochaux, Sevel

Nord

Renault – Guyancourt,

Dieppe, Douai, Flins,

Maubeuge

Toyota – Valenciennes

Bugatti - Molsheim

Spain

Ford – Valencia

Nissan – Barcelona

Opel – Zaragoza

PSA – Vigo

Renault – Palencia, Valladolid

Italy

Lamborghini – St. Agata

Bolognese

Fiat – Sevel Sud

Sweden

Volvo - Goteborg

Poland

Daewoo – Warschau

Fiat – Tichi

Volkswagen - Poznan

Czech Republic

Toyota – Kolin Hyundai – Ostrava Slovakia

Volkswagen – Bratislava

Kia - Zilina

Hungary

Audi – Gyor

Russia

Tagaz – Rostov

Avtovaz – Toliatti

Toyota – St. Petersburg

Volkswagen – Kaluga

GM – St. Petersburg

Hyundai – St. Petersburg

Turkey

Renault – Bursa

Hyundai - Izmir

Romania

Renault – Dacia

Slovenia

Renault – Revoz

Serbia

Fiat - Kragujevac

BURKE E PORTER | Customers in Europe

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USA

VW Chattanooga

Russia

General Motors,

Hyundai & TMMR St.

Petersburg

VW Kaluga

China

Dongfeng Peugeot

Citroën, Wuhan

VW, several sites

Thailand

General Motors,

Rayong

VW

Malaysia

VW

Brazil

PSA Porto Real

Renault Curitiba

VW Taubaté

VW Anchieta

VW Curitiba

Argentina

PSA Palomar

VW Pacheco

Renault Cordoba

India

VW Pune

Indonesia

PT Astra France

Motor, Jakarta

Morocco

Somaca, Casablanca

Renault, Tanger

Syria

Siveco, Homs

South Africa

FMCSA, Pretoria

General Motors, Struandale

VW Uitenhage

BURKE E PORTER | Customers Worldwide

More Waste Heat available from US Industry than all renewable energy sources combined

Energy Concern

Organic Rankine Cycle

• Rankine cycle, Steam cycle = high temperature & pressure

• Organic: use of cooling fluid = ‘Low’ temperature

• Waste heat transformed into electricity

• Working range ORC-medium: 80-150°C

ORGANIC CYCLE with REFRIDGERATOR

Organic Rankine Cycle

“Fuel” for ORC?

• Waste heat which is lost anyway:

• Engines, CHP (gas, bio gas, diesel, …): jacket cooling + exhaust gas

• Low pressure (waste) steam

• Industrial processes:

• Steel, glass industry

• Combustion processes (bio fuel, waste incineration )

• Exothermic processes in chemical industry

• Petrochemical industry: cool down distillates

• Power plants

• Geothermal applications, District heating, CSP

• Fluids and gases

Examples of Waste Heat flows - 1 Hot water:

Flow: 27,78 kg/s (100 m³/h / 440 GPM) Specific heat capacity water: 4,19 kJ/kgK T: cool down from 130°C to 90°C (266°F- 194°F) Thermal Power: 4 656 kWth / 15.9 MMBTU/h

Thermal oil:

Flow: 2,27 kg/s (11m³/h / 48 GPM) Specific heat capacity 2,5 kJ/kgK, Density: 742 kg/m³ T: Cool down from 200°C to 100°C ( 392°F- 212°F) Thermal Power: 567 kWth / 1.93 MMBTU/h

Examples of Waste Heat flows - 2

Low Pressure Steam: Flow: 0,8 kg/s (2,8 T/h) / 1,76 Lbs/s Evaporation heat 2106 kJ/kg at 150°C / 302°F T: Cool down from 150°C/ 302°F till 100°C/ 212°F and condense Thermal Power: 1 391 kWth / 4.75 MMBTU/h

Flue gases: Flow: 20,72 kg/s (100 000 Nm³/h) Specific heat capacity air at 200°C/ 392°F: 1,026 kJ/kgK, Density at 200°C/ 392°F: 0,746 kg/m³ T: Cool down from 260°C till 160°C ( 500°F- 320°F) Thermal Power: 2 126 kWth / 7.25 MMBTU/h

Efficiency of E-Rational ORC - 2

Carnot Efficiency : Whereas T1 is Hot Side (K) T2 is Cold Side (K) Carnot for cold side: i.e. 25°C/ 77°F = 298 K 400°C/ 752°F: 55,7% 30% (Power Plant) 200°C/ 392°F: 36,9% 120°C/ 248°F: 24,3% ORC: 8,5 – 11 % 90°C/ 194°F: 17,9% ORC: 6-9%

E-Rational ORC-1000 series

ISO US Metrics

Thermal Power Max 1000 kW 3.4 MMBTU

Heat source Hot Water, Thermal oil, Low Pressure steam

Input temperature 85°C-150°C 176°F-303°F

ORC Fluid Honeywell r245fa or Solkatherm SES36

Generator

Asynchronous 3 x 400 VAC 50 Hz

Asynchronous 3 X 480 VAC 60 Hz

Power Range Generator 55 - 70 - 90 - 110 - 132 kWe

Size L x W x H (mm) 10-20 Ft - High Cube

2,991 x 2438 x 2591 6058 x 2438 x 2896

2,991 x 2438 x 2591 6058 x 2438 x 2896

Weight kg/ Lbs 3,800 – 7,600 8,375 – 16,750

E-Rational ORC-1000/90 kWe (10 Ft) Skid - Model 2013

E-Rational ORC-1000/90 kWe (20 Ft) Container Model 2013

E-Rational ORC-4000

ORC-4000 series • One main platform, size 20 Ft Container • Outdoor use • Extended software control • Controlled and Seamless connection on the grid • Efficiency Depending on working conditions 6-13% • Expander- Generator set according to working conditions and available heat. Range 250kW-500 kWe • Asynchronous generator. • Built according to PED 97/22/EG • Option: Atex generator and work conditions

E-Rational ORC-4000 series

ISO US Metrics

Thermal Power Max 4000 kW 13.6 MMBTU

Heat source Hot Water, Thermal oil, Low Pressure steam

Input temperature 85°C-150°C 176°F-303°F

ORC Fluid Honeywell r245fa or Solkatherm SES36

Generator

Asynchronous 3 x 400 VAC 50 Hz

Asynchronous 3 X 480 VAC 60 Hz

Power Range Generator 250 -315-370-400- 450-500 kWe

260-300- 370- 400- 440-500 kWe

Size L x W x H (mm) 30-40 Ft - High Cube

9125 x 2438 x 2591 12192 x 2438 x 2896

9125 x 2438 x 2591 12192 x 2438 x 2896

Weight 15-25,000 kg 30-55,110 Lbs

E-Rational ORC-4000/250 kWe (20 Ft) Model 2012

E-Rational ORC-4000/260 kWe (30 Ft) Model 2014

E-Rational ORC-4000/260 kWe (30 Ft) Model 2014

ORC Software control

ORC Software control

ORC Software control

ORC Safety control

Software: Working Parameters set-up per machine

ORC Safety control

Hardware: Safety Valves

Electrical: Emergency stops

E-RATIONAL is a BEP Europe division

E-RATIONAL | Ten Briele 6 | 8200 Brugge | Belgium | T +32 50 40 85 40 | F +32 50 38 01 60 | www.e-rational.net

Industrial Heat Recovery Applications

Industrial Heat Recovery Application -1

Alstom, Norway (65°47’2”N) • International engineering company • Patented exhaust heat recovery in Aluminum Factories • ORC Pilot Project ORC1000-90 kWe

• Alcoa Aluminum Factory in Mosjøen, Norway • Hot water 90°C-70°C / 194°F-158°F • Thermal power 350 kW-1000 kW /1,2 -3,4MMBTU/hr • Cooling: cold water from Fjord 13°C/ 55°F • Power production 30-70 kWe (according to heat input)

• Pilot plant for proof of concept. • Operational June 2013 • Fairbanks: 64°50’37”N • Arctic Circle: 66°33’39”N

Industrial Heat Recovery Application - 1

Industrial Heat Recovery Application - 1

Industrial Heat Recovery Application - 2

Industrial Heat Recovery Application - 2

Proviron Base Chemicals, Ostend Belgium • Exothermic chemical process • Waste Steam recovery:

• Low pressure waste steam 3,5 bar max 3,5 T/h • Cooling: cold water • Power production: 200 kWe net • Yearly production > 1500 MWhe • > 1000 Tonnes CO2 Reduction per year • Water saving > 27000 m³/year

• Type: E-Rational ORC-4000/250 kWe ATEX • Operational since May 2012.

Industrial Heat Recovery Application - 2

Geothermal Applications

Geothermal Applications

• Source = medium to low enthalpy geothermal sources

• Water temperatures between 100 and 150 °C

• Power Plants : • Producing Electricity, opportunity to re-use cold side heat for nearby SPA, glasshouses, etc. if required • Low installation costs and low O&M requirements. • Ideal for small operators i.e. 250 kWe to 5 Mwe wanting to put the ORC next to the heat source • Simple and unattended operation

Biogas Applications

Biogas Application - 1

Biogas Application - 1

Vanheede Environmental Services, Quévy Belgium • Digester + 3 Biogas CHP Engines • Waste heat recovery from Engines (2 x 716 kWe + 1 x 1000 kWe)

• Hot water 88°C / 190°F • Heating of Digesters • Building heating • Water for showers,… • Remaining heat goes to ORC (320-450 kW/ 1-1.5 MMBTU/h)

• Cooling: air condenser • Power production: 40 kWe net • Yearly production > 340 MWhe • > 240 Tonnes CO2 reduction per year

• Type: E-Rational 1000-55kWe • Operational since July 2012

Biogas Application - 1

Biogas Application - 1

Biogas Application - 1

Biomass Applications

Biomass Applications

• Biomass = free fuel

• available nearly everywhere • can be stored for a long time • usually is free or wasted anyway

• CHP (Combined Heat and Power Plants) • Producing both Heat and Electricity • Possibities to re-use cold side heat,

• i.e. glass-houses, drying installations, chicken farm floor heating, .. • District Heating Networks for villages nearby • Saw dust drying • Swimming pools, hot springs, etc.

Biomass Application - 1

Biomass Application - 1

Centre Aquatique de Virton, Belgium

• Integration of ORC in heating of public swimming pool • ORC Project Type: ORC-500/30 kWe

• Hot water 90°C-70°C/ 194°C- 158°F • Thermal load 300 kW / 1.02 MMBTU/hr • Cooling: Swimming pool floor heating 35°C/ 95°F • Power production 22 kWe

• Delivery planned May 2014

Centre Aquatique de Virton

ORC 90°C

70°C

35°C

30°C Heat

exchanger

- Heating of public swimming pool - Re-use of ORC cooling side very efficient application

Pellet boiler

Heat exchanger - Shower

- Central heating system

Pool water ORC500 – 22kWe Hot water 300kWth 22 kWe production

Biomass Application - 2

Holzheizkraftwerk Hövelhof, Germany • Wood factory with saw dust as waste material • Wood fired boiler 5 MWth / 17.6 MMBTU • 1 MWe Turboden High temperature ORC (300°C/ 572°F) • Cooling of Turboden is heat input for E-Rational ORC • ORC Project Type: ORC-4000/315 kWe

• Hot water 90°C-70°C/ 194°F-158°F • Thermal load 4000 kW / 13.6 MMBTU • Cooling water circuit: Air cooled condensers • Power production 315 kWe

• Delivery done April 2014

Biomass Application - 3

Biomass Application - 3

Holzheizkraftwerk Oerlinghausen, Germany • Biomass boiler (wood) 3 MW/ 10,2 MMBTU/hr • Turboden 620 kWe High temperature ORC (>300°C / 572°F oil) • Cold side of Turboden powers district heating net (90°C-70°C / 194°F-158°F) • Excess heat in district heating to power E-Rational ORC • ORC 1000-90 kWe

• Thermal load: Max 1000 kW / 3.4 MMBTU/hr • Hot water from district heating (Excess heat) • Temperature: 90°C-70°C / 194°F-158°F • Cooling: Air condenser • Power production 70 kWe

• Delivery done March 2013

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BEP Europe | Questions ?

Turning waste heat

into

Clean Energy

Pre-study examples

Pre-study examples

1. Campine Belgium 2. Geothermal Application 3. District Heating Solution

Pre-study examples

1. Campine Belgium 2. Geothermal Application 3. District Heating Solution

Campine Beerse

- Amount of heat eliminated at quench? - Heat recuperation? - Process fluctuations? - Implementation possibilities on site? - Process impact?

Furnace

After burners

Quench

Mixing chamber Bag house

filter

Stack

Water

Air

1000°C

400°C 200°C

140°C

Furnace

After burners

Quench

Mixing chamber

Baghouse filter

Stack

Water

Air

ORC ORC4000 – 400kWe Hot water 3.5MWth Production 385kWe

Shell & tube Heat exchanger

ORC

1000°C

400°C

Air

co

ole

d c

on

de

nse

rs

ORC4000 – 400kWe Hot water 3.5MWth Production 385kWe

150°C

120°C

200°C 140°C

bypass

Campine Beerse

Pre-study examples

1. Campine Belgium 2. Geothermal Application 3. District Heating Solution

E-Rational Applications

Geothermal project De Kempen, Belgium •4 geothermal production wells •Geothermal brine temperature ≈ 124 °C •Return temperature to well ≈ 65°C •Available flow = 210 m³/h @ 16 – 21 bara •Heat recuperation by ORC •No cooling circuits available •Pre-study Available heat 11.15 MWth/ production well Total amount of heat = 44.6 MWth Local or centralized heat recovery?

Geothermal project De Kempen

•Geothermal brine contains salts and particles •No direct injection into heat exchangers of the ORC

Installation of extra heat exchanger(s) hot water circuit

•Compare smaller temperature differences

Geothermal project De Kempen •3 ORC machines •Parallel flows •3x ORC4000 •Total production = 960 kWe

Geothermal project De Kempen •3 ORC machines •Parallel flows •3x ORC4000 •Total production = 706 kWe

Geothermal project De Kempen •3 ORC machines •Serial flows •3x ORC4000 •Total production = 988 kWe

Geothermal project De Kempen •3 ORC machines •Serial flows •3x ORC4000 •Total production = 701 kWe

Geothermal project De Kempen

Cooling Ambient T

Parallel (65°C)

Parallel (85°C)

Serial (65°C)

Serial (85°C)

-10°C 9.30% 9.77% 9.43% 9.89%

0°C 8.74% 9.55% 8.88% 9.56%

10°C 7.40% 8.95% 7.78% 9.02%

35°C 3.23% 4.21% 4.56% 5.02%

Comparing efficiencies for different cooling temperatures:

Pre-study examples

1. Campine Belgium 2. Geothermal Application 3. District Heating Solution

E-Rational Applications

Holzheizkraftwerk Oerlinghausen, Germany •Biomass boiler (wood) 3 MW •Turboden 620 kWe High temperature ORC (>300°C oil) •Cold side of Turboden powers district heating net (90°C - 70°C) •Excess heat in district heating to power E-Rational ORC •ORC 1000 - 90 kWe

•Thermal load: Max 1000 kWth •Hot water from district heating (Excess heat) •Temperature: 90°C-70°C / 194°F-158°F •Cooling water circuit: Air cooled condenser •Power production 70 kWe

•Delivery January 2014

Holzheizkraftwerk Oerlinghausen

ORC

ORC

>300°C

Holzheizkraftwerk Germany, Oerlinghausen Biomass (wood) boiler 3MWth

District heating net

90°C

70°C

Turboden High temperature ORC Oil: >300°C 620kWe production ORC1000 – 90kWe

Hot water 1MWth 70 kWe production

Air

co

ole

d c

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nse

rs

Holzheizkraftwerk Oerlinghausen

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E-Rational BEP Europe NV Ten Briele, 6 B-8200 Brugge, Belgium Email: info@e-rational.net Phone: +32 50 408 540 Website : www.e-rational.net

BEP Europe

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