48
Carlo Minini Doc.: 14-COM.P-9-rev.0 Date: 20/03/2014 Organic Rankine Cycle (ORC) Technology for Energy Production Turboden’s experiences

Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

  • Upload
    others

  • View
    7

  • Download
    2

Embed Size (px)

Citation preview

Page 1: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Carlo Minini

Doc.: 14-COM.P-9-rev.0

Date: 20/03/2014

Organic Rankine Cycle (ORC) Technology for Energy Production

Turboden’s experiences

Page 2: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

1. The Company

2. The ORC

3. Turboden’s experiences

2

AGENDA

Page 3: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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.

Page 4: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

4

• 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

Page 5: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

5

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

Page 6: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 7: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Associations

Turboden cooperates with:

IEA (group CHP DHC)

WBA www.worldbioenergy.org/

AEBIOM www.aebiom.org/

BIOENERGY AUSTRALIA

Page 8: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Turboden at a Glance

8

Page 9: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

1. The Company

2. The ORC

3. Turboden’s experiences

9

AGENDA

Page 10: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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.

Page 11: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 12: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 13: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

ORC Plant in a Process of Cogeneration from Biomass

13

Page 14: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

HRS – High Electrical Efficiency Units

HRS for electricity generation and cogeneration from biomass

14

Page 15: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

HRS – High Electrical Efficiency Units

15

Page 16: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 17: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Advantages of Turboden ORC Turbogenerators

17

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)

Page 18: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Layout – Some Examples

TURBODEN 7 layout

TURBODEN 18 layout

18

TURBODEN 10 layout

Page 19: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

1. The Company

2. The ORC

3. Turboden’s experiences

19

AGENDA

Page 20: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

20

Turboden ORC Plants in the World

> 200 biomass applications in 26 countries

Page 21: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 22: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 23: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 24: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 25: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Sawmills

hot

water

SELECTION

DRYING

TRUNKS

PRODUCT

bark sawdust

BARKING PROCESSING

cold

water

PACKAGING

Thermal

oil BIOMASS

POWERED

BOILER

ORC

25

Electric

power

Page 26: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Wood Pellet Production

26

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

Page 27: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

MDF Production

27

Figure: Proposed scheme for MDF plant with ORC cogeneration unit

Page 28: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

CCHP – Combined Cooling Heating Power

28

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, …

Page 29: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Greenhouses

29

GREENHOUSE

GREENHOUSE

hot

water

hot

water

cold

water

Thermal

oil BIOMASS

POWERED

BOILER

ORC

Electric

power

Green

cuttings

Page 30: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Wine Production

30

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

Page 31: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

31

Reference Plant n.1 – Mirom, Belgium 1/2 Waste

to Energy

Page 32: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

32

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

Page 33: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

33

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

Page 34: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

34

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

Page 35: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Back-up slides

35

Page 36: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Wood Pellet Production

36

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

Page 37: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

37

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

Page 38: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

38

**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

Page 39: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 40: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 41: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 42: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

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

Page 43: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Bioenergy installations in the Italian towns

43

Source: Cogen Europe

Report 2012

Availability of raw

material and

support mechanism

have boosted the

sector

1.248 Italian towns with biomass plants

Page 44: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Italian Regulation – solid biomass

44

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 ?

Page 45: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Turboden – Facts & Figures

(Last update: January 2013) 45

Page 46: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

Combined Heat & Power (CHP) with Split system Standard

Sizes and Typical Performances

46

Page 47: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

47

HRS – High Electrical Efficiency Units

Page 48: Organic Rankine Cycle (ORC) Technology for Energy Production...Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are

Copyrig

ht

©

– T

urb

oden S

.r.l. A

ll rig

hts

reserv

ed

48

HRS – High Electrical Efficiency Units