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Carlo Minini
Doc.: 14-COM.P-9-rev.0
Date: 20/03/2014
Organic Rankine Cycle (ORC) Technology for Energy Production
Turboden’s experiences
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1. The Company
2. The ORC
3. Turboden’s experiences
2
AGENDA
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About Us
3
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 Mario Gaia, Professor of Energy at the
Politecnico di Milano, and today 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: to 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 UTC Corp., a worldwide leader in development,
production and service for aero engines, aerospace drive systems and power generation
gas turbines, to develop ORC solutions from renewable sources and waste heat
worldwide.
In 2013 UTC exits the power market forming strategic alliance with Mitsubishi Heavy
Industries.
In 2013 Mitsubishi Heavy Industries acquires from UTC Pratt & Whitney Power
Systems (now PW Power Systems, Inc.) and the affiliate Turboden.
Today Turboden s.r.l. and PW Power Systems, Inc. are MHI group companies to provide a
wider range of products and services for thermal power generation systems.
In 2013 Turboden’s Quality Management System gets certified to ISO
9001:2008.
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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
• 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
Over 30 Years of Experience
• MHI acquires the majority of
Turboden. Italian quotaholders
stay in charge of management
• Today - Over 250 ORC plants
in the world, 200 in operation
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1984 – 40 kWel ORC
turbo-generator for a solar
plant in Australia
1987 – 3 kWel ORC turbo-
generator for a biomass
plant in Italy
2008 – 3 MWel ORC
turbo-generator for heat
recovery on a waste
incinerator in Belgium
1988 – 200 kWel ORC
geothermal plant in
Zambia
2009 – First 100 plants
and first installed 100
MWel
2010 – First plant
overseas
2013 – Over 250 ORC
plants in the world
Over 30 Years of Experience
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Turboden strong points
6
• 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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Associations
Turboden cooperates with:
IEA (group CHP DHC)
WBA www.worldbioenergy.org/
AEBIOM www.aebiom.org/
BIOENERGY AUSTRALIA
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Turboden at a Glance
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1. The Company
2. The ORC
3. Turboden’s experiences
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AGENDA
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standard units from 200 kW to 10 MW
customized solutions up to 15 MW
10
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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The Thermodynamic Principle: The ORC Cycle
The turbogenerator uses the 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) (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.
11
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ORC Plants – Performance
Gross electric efficiency: up to 24%
Overall energy efficiency: 98%
100%
18 to 24%
2%
80 to 74%
Thermal power
from thermal oil
(or other heat
carrier)
Thermal power to
heat users
Gross electric power
Thermal losses (insulation and
generator losses)
12
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ORC Plant in a Process of Cogeneration from Biomass
13
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HRS – High Electrical Efficiency Units
HRS for electricity generation and cogeneration from biomass
14
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HRS – High Electrical Efficiency Units
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Why High Molecular Mass Working Fluid Instead of 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
16
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Advantages of Turboden ORC Turbogenerators
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Technical advantages
High cycle efficiency
Very high turbine efficiency (up to 90%)
Low mechanical stress of the turbine due to the low peripheral speed
Low RPM of the turbine allowing the direct drive of the electric generator without
reduction gear
No erosion of blades, thanks to the absence of moisture in the vapor nozzles
Operational advantages / results
Simple start-stop procedures
Automatic and continuous operation
No operator attendance needed
Quiet operation
Partial load operation down to 10% of nominal power
High efficiency even at partial load
Low O&M requirements: about 3-5 hours / week
Long life
High Availability (confirmed by more than 2 million hours of operation)
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Layout – Some Examples
TURBODEN 7 layout
TURBODEN 18 layout
18
TURBODEN 10 layout
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AGENDA
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Turboden ORC Plants in the World
> 200 biomass applications in 26 countries
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Solid biomass CHP applications with ORC
some CHP applications size range
District heating 0.2 - 2 MWe
Sawmilll - wood industry 0.6 - 2 MWe
MDF 1 – 1.3 MWe
Pellet industry 0.6 - 2 MWe
CCHP Public buildings /
Industrial processes 0.2 – 1.8 MWe
wood biomass: sawdust, woodchips, bark, treated wood
other biomass: dried sewage sludge, green cuttings, rice husk,
vinasse and vine cuttings, wood industry waste material etc …
waste material
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What we have done up to now*
* March 2014
272 Turboden ORC References in the World in 32 Countries
235 applications in biomass in 26 Countries
By applications: By sizes:
- 108 District heating From 200 kWe to 3 MWe < 400 kWe 7
- 43 Sawmilll and wood industry From 600 kWe to 6,5 Mwe 0,4 – 1 MWe 115
- 3 MDF (Medium Density Fiber) From 1 MWe to 1,3 MWe 1 MWe power only (12HRS) 22
- 33 Pellet industry From 600 kWe to 2 MWe 1 - 2 MWe 82
- 5 Public buildings: CCHP (Combined Cooling heating Power)
From 600 kWe to 1,8 MWe 2 - 5 MWe 26
- 15 CCHP In industrial processes (Agroindustry; Wood indiustry,..)
From 200 kWe to 1,3 MWe > 5 MWe 10
- 24 Power Only 12 HRS: 1 MWe Pure Cycle 3
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Biomass – Fuels & Applications
Fuels
Wood biomass: sawdust, woodchips, bark, treated wood
Other biomass: dried sewage sludge, green cuttings, rice husk,
vinasse and vine cuttings, wood industry waste material etc …
Waste material
Heat Consumers
District Heating networks
Timber drying in sawmills
Sawdust drying in wood pellet factories
MDF/PB Producers
Air pre-heating in MDF industry
Refrigeration
Greenhouses
Wine industry
23
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District Heating Networks
WITHOUT ORC
WITH ORC
HEAT
USER
BIOMASS
POWERED
BOILER BIOMASS
hot
water
cold
water
HEAT
USER
BIOMASS cold
water
hot
water
BIOMASS
POWERED
BOILER
Thermal
oil
Electric
power
ORC
24
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Sawmills
hot
water
SELECTION
DRYING
TRUNKS
PRODUCT
bark sawdust
BARKING PROCESSING
cold
water
PACKAGING
Thermal
oil BIOMASS
POWERED
BOILER
ORC
25
Electric
power
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Wood Pellet Production
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BELT DRYER
Pellet
PELLET
READY TO BE
PACKAGED
Suitable
granulometry
UR 40%
UR < 13%
BIOMASS
POWERED
BOILER
SELECTION/
SORTING
CHIPPING BARKING
AIR COOLING/
DEDUSTING
PELLET
MAKING PRESS
ORC
DEDUSTING/
SELECTION/
REFINING
MILLING
Thermal
oil
Electric
power
TRUNKS
cold
water
hot
water
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MDF Production
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Figure: Proposed scheme for MDF plant with ORC cogeneration unit
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CCHP – Combined Cooling Heating Power
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cold
water
ABSORPTION
CHILLER
hot
water
ELECTRIC
POWER
DISTRICT
HEATING
cold
water
COOLING
SYSTEM
BIOMASS
POWERED
BOILER
BIOMASS
ORC
Thermal
oil
USE IN
PUBLIC
BUILDING,
HOTEL, …
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Greenhouses
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GREENHOUSE
GREENHOUSE
hot
water
hot
water
cold
water
Thermal
oil BIOMASS
POWERED
BOILER
ORC
Electric
power
Green
cuttings
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Wine Production
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Vine Growing
Grape production
Land yearly upkeeping cutting
Rasping
Sweet Vinasse
Grape juice
Fermented Vinasse
Grape stalks
DISTILLING
Grappa and Alcohol
Exhaust Vinasse
Skins Vinasse
BIO
MA
SS T
O E
NER
GY
PR
OD
UC
TIO
N
Fermentation
WH
ITE
Pressing
RED
Pressing Fermentation
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Plant type: heat recovery from pressurized water boiler in urban waste incinerator
Customer: MIROM
Location: Roeselare, Belgium
In operation since: II quarter 2008
Availability: > 98%
Heat source: hot water at 180°C (return at 140°C)
Cooling source: water/air
Total electric power: 3 MW
Net electric efficiency: 16.5%
Non flammable working fluid: to meet customer’s requirement
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Reference Plant n.1 – Mirom, Belgium 1/2 Waste
to Energy
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Reference Plant n.1 – Mirom, Belgium 2/2
Initial installation in operation since: 1976
Treatment capacity: 62.000 ton/year urban waste
Boilers: 2x 8MWth
Use of heat: hot water at 180°C (return at 140°C)
District heating since: 1986, 21 customers, 7.5 km
ORC project started: 2006, in operation since 2008 in parallel to district heating use
Before After
Waste
to Energy
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Reference Plant n.2 – ITC, Turkey
Location: Ankara (Turkey)
Client: ITC-KA Enerji Uretim Sanayi Ve Ticaret A.S.
Start-up: Q1 2014
Heat source: industrial waste gasification
Source temperature: 315°C (thermal oil)
Water temperature (in/out): 25-35°C
Electric Power: 5.5 MWel
Net electrical efficiency: 25%
Project description: the high efficiency Turboden 55-HRS
unit exploits the heat from the combustion of the synthesis
gas generated from industrial waste.
The gas is burned in a boiler that heats up the thermal oil
that carries the 20 MWt input into the ORC module.
The cooling is done through wet cooling towers.
The client is installing a second 55-HRS unit and is looking at
a number of 110-HRS units (11 MWel each) to use with
municipal waste in the near future
Waste
to Energy
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Other References
Plant type: Power only - Waste incineration
Customer: Sasu Alcea, Groupe Seche Environnement
Source temperature: 200°C pressurised water
In operation since: under construction
Total electric power: 2700 kW
Cooling water Temp. (In/Out): 24 - 32°C
Plant type: Power Only - Waste incineration (biosolids from sewage water treatment)
Customer: C.O. Falter Construction Corp.
Location: Menands, NY, USA
In operation since: III quarter 2012
Total electric power: 1000 kW
Cooling water Temp. (In/Out): 29 - 41°C
Plant type: CHP - Waste Incinerator Plant
Customer: Agrivis Spa
Location: Nocera Inferiore (SA), Italy
In operation since: IV quarter 2005
Total electric power: 500 kW
Cooling water Temp. (In/Out): 60 - 80°C
Waste
to Energy
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Back-up slides
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Wood Pellet Production
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BELT DRYER
Pellet
PELLET
READY TO BE
PACKAGED
Suitable
granulometry
UR 40%
UR < 13%
BIOMASS
POWERED
BOILER
SELECTION/
SORTING
CHIPPING BARKING
AIR COOLING/
DEDUSTING
PELLET
MAKING PRESS
ORC
DEDUSTING/
SELECTION/
REFINING
MILLING
Thermal
oil
Electric
power
TRUNKS
cold
water
hot
water
Biomass
References
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Pellet process and Turboden ORC integration
ORC Flexibility and Reliability
Pellet Manufacturing Process
The integration between the Turboden ORC and an existing or brand new Pellet manufacturing process gives the possibility to
diversify the business producing, at the same time, Pellet and Electrical Energy from
Renewable Sources (i.e. biomass)
Industrial process productivity needs
Biomass
References
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**Assuming Turboden CHP and Belt dryer configuration
•Source: Bioenergy International May 2011, Prodesa Medioambiente – “Cogeneracción y producción de pellet”
Sample case:**
•ORC Unit: Turboden 10 CHP integrated in a Pellet plant
•Pellet production capacity = 4 tons/h
•Pellet production = 30.000 tons/y
•Biomass Consumption = 57.500 tons/y
•Boiler installed = 5,2 MWth
•Electrical power installed = 1 MWel
•Thermal power output = 4.1 MWth at 60/80°C
Dimensioning Parameters
ORC Size Pellet production capacity**
Turboden 10 CHP Split (4100 kWth) 30.000 t/y*
Turboden 14 CHP Split (5340 kWth) 42.000 t/y*
Turboden 22 CHP Split (9598 kWth) 85.000 t/y
Turboden 30 CHP Split (13636 kWth) 120.000 t/y
Biomass
References
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Example of Pellet application
Erta in Spain - EA
Context / Special Feature
A/ Pelletisation process
- Annual production: 30000t/year
- 4 silos of 500t each for bulk distribution
- 15kg bags production
- Max pellet production: 4 t/h
- Hot water to dry saw from 50% to 10%
B/ Specificity: Application Pellet
- General contractor: PRODESA
- belt dryer supplier: Swiss Combi
- Pelletisation system supplier: Promill
Model: TD 7 CHP
Client: ERTA - Energías Renovables de Tarazona
Start up: 2011
Location: Tarazona della Mancha - Spain
Fuel: Wood chips
Electric power: 729 kWe
Thermal Use: drying belt in pelletisation process
Thermal power: 3145 kWth
Water Temperature: 60-80 °C
Boiler supplier: Sugimat
Biomass
References
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Example of Pellet application
Model: TD 6 CHP
Client: Prodesa Medioambiente
Start up: 2012
Location: Pontedeva - Spain
Fuel: Forestal Biomass
Electric power: 617 kWel gross
Thermal Use: drying belt in pelletisation process
Thermal power: 2600 kWth
Water Temperature: 60-80 °C
Special Feature
Annual production: 20000 t/year
Pellet production capacity: 2.5 t/h
Pontedeva in Spain - PD
Biomass
References
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Example of Pellet application
Model: TD 12 HRS
Client: Italiana Pellets SpA
Start up: 2011
Location: Corana (PV)
Fuel: Wood chips
Electric power: 999 kWe
Thermal power: 3040 kWth
Water Temperature: 25-35 °C
Special Feature
Pellet production capacity: 100.000 t/a
Corana in Italy - IP
Biomass
References
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Example of Pellet application
Mudau in Germany - MU
Context / Special Feature
A/ Pelletisation process
- Max pellet production: 6t/h
- Hot water to dry saw from 50% to 10%
B/ Specificity: Application Pellet
- Biomasse boiler: 6570 kWth
- Cogénération withORC:
5335kWth
1187 kWe (brut); 1124 kWe (net)
- belt dryer supplier: Stela
- Pelletisation system supplier: Salmatec
Model: T1100
Client: BIO-ENERGIE MUDAU GMBH & CO.KG
Start up: June 2006
Location: Mudau - Germany
Fuel: Wood chips
Electric power: 1187kWe
Thermal Use: drying belt in pelletisation process
Thermal power: 5335kWth
Water Temperature: 60-85 °C
Boiler supplier: Kohlbach
Biomass
References
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Bioenergy installations in the Italian towns
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Source: Cogen Europe
Report 2012
Availability of raw
material and
support mechanism
have boosted the
sector
1.248 Italian towns with biomass plants
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Italian Regulation – solid biomass
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Biomass since 2013 - Decree 6 July 2012
2 different incentives for wood and by products
annual cap for period 2013-2015: 145 MWe (biomass, biogas, bio-oil)
2% annual reduction incentive value
Size Incentive (20 years)
[€/MWh]
Bonus CHP
[€/MWh]
Other bonus
[€/MWh]
< 300 kWe Feed-in tariff 229 - 257 40-10 30
300 kW – 1 MWe Feed-in tariff 180 - 209 40-10 30
1 MWe – 5 MWe
Feed-in tariff
or Feed-in
premium
133 - 161 40-10 60
> 5 MWe BID 122 - 145 40-10 60
more oriented to CHP than before more oriented to small sizes more barriers (e.g. register, cap…) … and after 2015 ?
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Turboden – Facts & Figures
(Last update: January 2013) 45
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Combined Heat & Power (CHP) with Split system Standard
Sizes and Typical Performances
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HRS – High Electrical Efficiency Units
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HRS – High Electrical Efficiency Units