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Turboden ORC energy recovery:best practices in energy intensive industries
Alessandro Foresti – Turboden Director
Energy recovery in industry – Best practice to implemen tionDuisburg, Wednesday 12th June 2013
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• ORC technology
Features and advantages
• About Turboden
30 years of experience
• Application
Turboden ORC references
H-REII and H-REII Demo: Demonstration WHR plant in steel industry
• References in Energy Intensive Industries
Interface with process
References
First glance at economics
• Conclusion
Agenda
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� standard units from 200 kW to 10 MW
� customized solutions up to 15 MW
� standard units from 200 kW to 10 MW
� customized solutions up to 15 MW
3
electricity
heat
Biomass
Waste-heat
Geothermal
Solar
Turboden ORC
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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 organicworking fluid in the evaporator (8→3→4). The organic fluid vapor powers the turbine (4→5), which isdirectly coupled to the electric generator through an elastic coupling. The exhaust vapor flows throughthe regenerator (5→9) where it heats the organic liquid (2→8). The vapor is then condensed in thecondenser (cooled by the water flow) (9→6→1). The organic fluid liquid is finally pumped (1→2) to theregenerator and then to the evaporator, thus completing the sequence of operations in the closed-loopcircuit
Turbine
Generator
Rigenerator
Water
Condenser
Evaporator
Pump
Heat carrier
Electric EnergyTe
mp
era
ture
Entropy
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ORC vs. traditional steam cycle
5
Water / Steam
Tem
pera
ture
Entropy
Tem
pera
ture
ORC
Entropy
SATURATION CURVE WITH PARALLEL SLOPES
Dry vapour expansion
No need to superheat
Moderate temperature/pressure
SMALL ENTHALPY DROP
Large slow turbine Rigeneration
High efficiency
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Advantages of Turboden ORC Heat Recovery Plants
5
• No erosion of blades, low mechanical stress of the turbine
• No corrosion issues (use of non aggressive working fluid)
• Ease of integration in main process (by-pass); do not affect plant operations
• Demonstrate very good partial
load behaviour (see curve)
• Do not consume water
• No need of water treatment
• Selection of more appropriate
working fluid
• Low O&M requirements
• ORC plants remotely monitored 20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 20% 40% 60% 80% 100%
OR
C A
ctu
al
Eff
icie
ncy
/ O
RC
No
min
al
Eff
icie
ncy
Actual Load / Nominal Load
ORC Part Load efficiency
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7
• 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
• First direct exchange ORC 600 KWeconnected to Diesel Engine
• 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
• MHI acquires the majority of Turboden.Italian quotaholders stay in charge of management
•Today - Over 250 ORC plants in the world, 200 in operation
Over 30 years of experience
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Oil&Gas Player
Russia
Oil&Gas Player
Canada
8
In Europe
Germany 80
Italy 71
Austria 30
Spain 7
etc…
Turboden ORC units in the world 253 - 28 Countries
Installed power 333 MW
Wood Biomass 221 units (300 kW ÷ 6.5 MW)
Combined cycles 13 units (500 kW ÷ 4.5 MW)
Industrial heat recovery 9 units (700 kW ÷ 7 MW)
Municipal waste treatment 4 units (500 kW ÷ 6 MW)
Geothermal 6 units (1 MW ÷ 6 MW)
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A good energy efficiency practice: decrease final
energy consumption (electricity, heat, etc.)
recovering EII waste heat streams
ORC generator
process or thermal
users: both civil and industrial
Heat Exchanger
Energy Intensive Industries
wasted heatgas, liquid,
vapour
Electricity
Thermal energy
Thermal Energy
ORC Heat Recovery in Energy Intensive Industries
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ORC interfaces with the process
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ORC battery limit
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Interfaces with process: heat carriers
Heat carriers:• Thermal oil• Saturated steam• Water (e.g. geothermal, moderate temperature heat recovery)• Molten Salts (e.g. CSP)• …
Heat carrier loop features :• Multiple heat sources• Layout flexibility• Ease of operation (process upset tolerance)• Energy buffer• …
Direct heat exchange with hot gas stream is feasible,under certain conditions…
Layout, heat exchanger size, 1 source to 1 ORC, etc.
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Heat Recovery In Energy Intensive Industries: Turboden approach
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Several schemes can be studied to maximize electric power output
minimizing the investment cost
Collaboration with process owner and heat exchanger suppliers to best
match the specific plant features
Flexible ORC solutions :
• different working fluids (temperature ranges, ORC size, etc.)
• different heat carriers (temperature ranges, specific issues, etc.)
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Holcim Slovakia– Holcim GroupSite: Rohoznik (Slovakia)
Client: Holcim Slovensko A.S.
Status: to be started up end 2013 / beginning 2014
Heat Source: exhaust gas from PH and CC
Heat carrier: thermal oil
Cooling: water condenser + wet cooling tower
Electric power: 5 MWel
Slovakia
Holcim Romania – Holcim GroupClient: Holcim Romania - Alesd
Clinker production capacity: ≈ 4.000 ton/day
Heat source: exhaust gas @ 360°C (PH) and hot air @ 250 °C (CC)
Thermal oil (PH) and pressurized water (CC) heat re covery loops
Cooling: water condenser + wet cooling tower
ORC electric power: ~ 4 MWe
Started up: July 2012 (4,200 working hours)
Availability: >98%
Turboden Heat Recovery references
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Cimar - Italcementi GroupSite: CIMAR – ITALCEMENTI GROUP (Morocco)
Clinker production capacity: ≈ 5.000 ton/day
Heat source: PH exhaust gas at 330°C
Cooling: water condenser + air-coolers No water consumption
ORC electric power: 2 MWe
In operation since IV quarter 2010
Working hours: 16.000 h
Availability: >98%
The plant is being hybridized with CSP (Concentrated Solar Power) taking
advantage of the ORC extra capacity
Turboden Heat Recovery references
AGC Glass EuropeSite: Cuneo - Italy
Client: GEA Process Eng
Final Client: AGC Glass Europe
Started up: March 2012
Heat source: gas @ 500°C from glass production process
Heat carrier: thermal oil
Cooling: water condenser + air-coolers
Electric power: 1.3 MWel
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Refractories – RHI Group Austria
Client: RHI GROUP (Radenthein - Austria)Refractory production capacity: ≈ 250 ton/day Heat source: refractory ovens exhaust gas @ 500 °CGas cooled down to ca. 150 °CORC electric power: ca. 1 MWeStarted up: Q1 2009
Turboden Heat Recovery references
Pipeline compressor stationHeat recovery from Solar CENTAUR gas turbine in a Gas Compressor station in CanadaGas Turbine prime power: 3.5 MWeGas Turbine efficiency: 28%ORC electric power: 1MWe General Contractor: IST (Innovative Steam Technologies)Final Client: TransGasIn operation since IV quarter 2011
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Billet reheating furnace at steel rolling mill
Client: NatSteel – Tata GroupSite: SingaporeStarted up: February 2013
Heat source: exhaust gas from LFO combustion, @ 400°CDirect exchange between exhaust gas and working fluid ORC electric power: ~ 0.7 MW
16
Heat Recovery Reference in Steel Industry -Direct exchange
4th Direct exchange ORC unit in operation
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� H-REII (2010-2012) �Quantify the heat recovery potential inthe Italian EIIs (pioneer EU project)�Promote energy efficiency policy inItaly (disseminating best practice)
Extending from Italy to Europe
� H-REII DEMO (2012-2014)�Quantify the heat recovery potential inthe European EIIs�Promote energy efficiency policy inEurope (disseminating best practice)�Support demonstration of ORC heatrecovery plant in the Steel Industry
European Focus on Energy Efficiency:H-REII and H-REII DEMO projects.
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Expected start up:
Q1 2014Electric Arc
Furnace(EAF)
Heat exchanger
Industrial thermal userThermal energy
~ 30 t/h steam at 27 bar - 245°C
Exhausted gases
ORC3 MWe
Electric energy
Reduce consumption
33%67%
H-REII Demo – Demonstration Plant
ESF - Riesa (Germany)
Tenova RE Energy
GMBH
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First glance at economics: CAPEX / OPEX
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ORC unit� ORC module is only a portion of the waste heat
recovery system � Specific investment cost depends on several
factors, most importantly the ORC size , but also specific applications , Client’s requirements and needs , cooling system, etc.
� ORC only OPEX in the range of 2-5 % of ORC Capex / year
Process heat exchanger, heat carrier loop and balance of plant
Specific investment cost highly affected by project-related and site-related factors, such as:
• Main process characteristics • Potential multiple heat sources• Layout constraints • Climate conditions at the installation site• Grid connection (voltage, distance) • Civil works• Erection cost• …
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Recomended policy actions:
• funding and guarantees to reduce barriers in project financing
• preferential prices for EII must promote investments for energy efficiency
• dissemination : increase industrial players awareness of BAT (ORC, etc.)
20
Barriers and Prospects
ORC waste heat recovery in European EII is a best practice:
• of energy efficiency for a sustainable industry
• increasing industries competitiveness
• promoting a new European supply chain to export
• helping in saving/creating new jobs
… but investment payback time is limited by:• investment cost • electricity price with preferential rates for EII in some countries• Incentives for energy efficiency in industry only in few Member States• lower operating hours due to economic downturn
Thanks for your attention!
For further information contact:
[email protected]@turboden.it
+39 030 3552001www.turboden.com
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Backup
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ORC: Organic Rankine Cycle
23
CONDENSER
FEED PUMP
EVAPORATOR
ORC broad definition: «a cycle with a change of phase (liquid to vapour and viceversa)
utilizing a working fluid different from Water …(hence including siloxanes,
hydrocarbons,…)»
EXPANDER
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rved Factors involved :
• Cycle efficiency
• ORC Size
• Cost
• Safety
• Environment
Silicone based
•Small ORC size (<4 MWe) •Biomass• Moderate & high temperature HR (e.g. gas turbine exhaust, process waste gas)• Concentrated solar power
Fluorinated
• Geothermal• Low temperature HR (e.g. engine jacket water, process hot water)
•Big size of unit•Low cost, but some of them more flammable• Low, moderate & high temperature HR andbig biomass plants• Geothermal
Hydrocarbons
SOURCE TEMPERATURE
ORC Working Fluids
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Organic Fluid vs. 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
25
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Turboden – a group company of MHI
26
EnergyAircraft Ship & OceanSpace
Transportation Material Handling Environment Automotive
Industrial Machinery Infrastructure Living & Leisure Defense
Mitsubishi Heavy Industries is one of the world's leading
heavy machinery manufacturers, with
consolidated sales of over $28 billion (in fiscal 2011).
MHI's products and services encompass shipbuilding,
power plants, chemical plants, environmental equipment,
steel structures, industrial and general machinery, aircraft,
space systems and air-conditioning systems.
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Turboden, more than 30 years in the ORC
27
40 kW solar 3 kW CHP biomass
1987
3 MW waste incinerator
2008
Cement factories up to 7 MW
2013
Application in cement up to 7 MW
Perth, Australia Milan, Italy
Roeselare, Belgium Alesd, Romania
From small R&D modules to large industrial installations
1984
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Turboden – Facts & Figures
(Last update: January 2013) 28
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References in Renewables 1/2
29
Site: British Columbia (Canada)Client: West Fraser TimberStatus: under construction Heat Source: biomass furnace burning wood chipsHeat carrier: Thermal oil Electric power: 2 sites with 2 x 6.5 MWel
Net electric efficiency: ∼25%Remote Locations
Plant type: geothermal prototype with supercritical cycle
Client: Enel Green Power - Italy
Started-up: March 2012
Heat source: hot water at 150°C nominal
Cooling device: ‘dry & spray’ condenser
Electric power: 500 kWel
Working fluid: refrigerant
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Client: SWM - StadtWerke München (public utilities company)
Site: Bavaria, Germany
Started-up: February 2013
Heat source: geothermal fluid at 140°C
Cooling device: air condensers
Electric power: 5+ MWel plus 4 MWth decoupling for
district heating
Working fluid: refrigerant
References in Renewables 2/2
Client: Hochtief Energy Management GmbH
Sites: Dürrnhaar (München)
Kirchstockach (München)
Started-up: December 2012 and March 2013
Heat source: geothermal fluid at 138°C
Cooling device: air condensers
Total electric power: 2 x 5,600 kW
Working fluid: refrigerant
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ORC heat recovery applications
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Industrial heat recovery demands ORC can guarantee
Main process reliability must not be
affected
Process interface with easy decoupling
Plant operators must not be
distracted
Simple, fail-safe and automatic system
Matching actual working regimes
(variable, semi-batch, upset)
Flexible / modulating operation
+ suitable process heat capture and transfer equipment
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References in heat recovery on industrial process
Site: Ankara (Turkey)Client: ITC-KA Enrji Uretim Sanayi Ve Ticaret A.S.Status: unit to be started up IV quarter 2013Heat Source: waste gasifierHeat carrier: t hermal oilCooling: water condenser + wet cooling towerElectric power: 5.5 MWelNet electric efficiency: ∼25 %
32
Site: Cuneo - ItalyClient: GEA Process Eng Final Client: AGC Glass EuropeStarted up: March 2012Heat source: gas @ 500°C from glass production
processHeat carrier: thermal oil Cooling: water condenser + air-coolersElectric power: 1.3 MWel
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References in heat recovery and combined cycle
33
Site: Pisticci Scalo (Italy)Client: Ricciarelli S.p.A.Started-up: June 2012Heat Source: 3x17 MW Diesel engines, gas @ 350°CHeat carrier: thermal oil Cooling: water condenser + wet cooling towerElectric power: 3.8 MWel
Project description: 3 thermal oil boilers recover heat from exhausts coming from palm oil-fed reciprocating engines.
Site: Roeselare-Belgium
Client: MIROM
Started up: II quarter 2008
Heat source: municipal solid waste incinerator
Heat carrier: pressurized water at 180 °C (back 140 °C)
Cooling: water condenser + air coolers
Electric power: 3 MWel
Net electric efficiency: 16,5%
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Heat recovery from Solar CENTAUR gas turbine
General Contractor: IST (Innovative Steam Technologies)Final Client: TransGas
Site: Rosetown - Saskatchewan, Canada
In operation since November 2011
�Gas Turbine prime power: 3.5 MWe
�Gas Turbine efficiency: 28%
�ORC heat carrier: thermal oil
�ORC electric power: 1M We
Gas compressor station
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Refractory
Heat recovery from refractory ovens exhaust gas
Client: RHI GROUP Site: Radenthein, Austria
In operation since February 2009
�Refractory production capacity: ≈ 250 ton/day
�Heat source: exhaust gas @ 500 °C
�Gas cooled down to ca. 150 °C
�Heat carrier: thermal oil
ORC electric power: ca. 1 MWe
35
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Billet reheating furnace at steel rolling mill
Client: NatSteel – Tata GroupSite: Singapore, Thailand
In operation since February 2013
� Heat source: exhaust gas from LFO combustion, @ 400°C
� Direct exchange between exhaust gas and working fluid
� ORC electric power: ~ 0.7 MW
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Steel
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H-REII DEMO:
Demonstration plant
Client: ESF Elbe Stahlwerke Feralpi GmbH Site: Riesa, Germany
Expected start-up within I quarter of 2014
Heat recovery on Electric Arc Furnace (Batch process)Heat source: ~ 20 tons/h saturated steam at 27 bar @ 245°CElectric power : 3 MW
37
ORC
200 - 900 °°°°C
150 - 350 °°°°C
300 - 1600 °°°°C
Target:3-5% of the
EAF installed power
Industrial thermal user
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Client: Holcim Romania - Alesd
Clinker production capacity: ≈ 4.000 ton/day
Heat source: exhaust gas @ 360°C (PH) and hot air @ 250 °C (CC)
Thermal oil (PH) and pressurized water (CC) heat re covery loops
Cooling: water condenser + wet cooling tower
ORC electric power: ~ 4 MWe
Started up: July 2012 (4,200 working hours)
Availability: >98%
38
Romania
PH boiler AQCboiler
Reference case: Holcim Romania
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Reference case: Holcim Slovakia
Site: Rohoznik (Slovakia)Client: Holcim Slovensko A.S.Status: to be started up end 2013 / beginning 2014Heat Source: exhaust gas from PH and CCHeat carrier: thermal oilCooling: water condenser + wet cooling towerElectric power: 5 MWel
39
Project description: The Rohoznik cement plant has a clinker capacity of around 3600 ton/day. Heat is recover both from the pre-heater and the clinker cooler.
Slovakia
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Newest Reference case
Customer Not Disclosable
Heat source: PH and CC gas waste heat recovery ORC electric power: ca. 7 MWeSite: North America
40
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Reference case: Italcementi Group
Client: CIMAR – ITALCEMENTI GROUP (Morocco)
Clinker production capacity: ≈ 5.000 ton/day
Heat source: PH exhaust gas at 330°C
Cooling: water condenser + air-coolers
No water consumption
ORC electric power: ∼∼∼∼2 MWe
41
Air-coolersORC building
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In operation since IV quarter 2010
Working hours: 16.000 h
Availability: >98%
42
The plant is being hybridized with CSP (Concentrated Solar Power) taking advantage of the ORC extra capacity:
Reference case: Italcementi Group
By courtesy of Italcementi Group
215 m
11 m
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Total WHRS investment cost• Influenced by many specific project related factors: size, ambient temperature, exhaust gas temperatures and flows, number of heat source, layout, electric connection, water availability, erection cost, etc.
Total installed cost of 3,000 €/kWnet +/-30% can be used as ball park figure
Economical Feasibility is driven mainly by• WHRS investment cost
• Electricity value may range between 0,13 €/kWh (e.g. in Italy with White certificates) to less than 0,05 €/kWh
• Operating hrs: the grater, the better (typical values are 7,500 hrs/annum)
• O&M cost: for complete ORC based plant in the range of 1 % of Capex/year (approximately half of steam based plant)
43
First glance at economics
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Heat recovery systems economics
44
ORC unit
� ORC module is only a portion of the waste heat recovery system
� Specific investment cost depends on several factors, most importantly the ORC size, but also
specific applications, Client’s requirements and needs, etc.
� According to the size, specific investment ranges from about 700 - 800 € / kW, for units rated
around 5 MW, to more than 1,400 € / kW for units rated less than or equal to 1 MW.
� ORC O&M in the range of 2 – 5 % of Capex / year
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Heat recovery systems economics
45
Process heat exchanger, heat carrier loop and balance of plant
Specific investment cost highly affected by project-related and site-related factors, such as• Main process characteristics (continuous or batch)
• Potential multiple heat sources
• Layout constraints
• Climate conditions at the installation site
• Grid connection (voltage, distance)
• Civil works
• …
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Conclusions
46
ORC
� allows to take advantage of mid and low-temp. sources from 3 MW to 50 MW
� guarantees high efficiency, reliability and minimum O&M
Turboden
� is European leader in ORC turbogenerators
� has track records in Energy-Intensive Industries, teaming up with specialized
engineering companies and plant makers for specific sectors
…
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47
Conclusion:Turboden ORC based Waste Heat Recovery
Economic & Technical Feasibility
Automatic, Unmanned Operation Minimal / No impact on cement production processLow operation and maintenance requirements / costNo water consumptionPossibilities of attractive Payback, IRR, and NPV Optimization of the complete solution together with main heat exchangers suppliersTailor made solutions
References in Cement plants
Proven Reliability
Over 250 ORC’s globallyOver 300 MWe installedOver 5 Million hours of operation