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Electricity production from Biomass using Organic Rankine Cycle
Energy Managers days 2008, 8- 9 April 2008 – Portorose , Roberto Bini
Turboden T600 – CHP (600 kWel)
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Agenda
• ORC Cycle: thermodynamics and Advantages
• The split system
• Typical applications in Biomass cogeneration
• New technical solutions and applications
ORC Cycle The split system Typical applications New solutions
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ORC Plants in Biomass cogenerationD
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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 (8→3→4). The organic fluid vapour powers the turbine (4→5), which is directly coupled
to the electric generator through an elastic coupling. The exhaust vapour flows through the regenerator (5→9)
where it heats the organic liquid (2→8). The vapour is then condensed in the condenser (cooled by the water
flow) (9→6→1). The organic fluid liquid is finally pumped (1→2) to the regenerator and then to the evaporator,
thus completing the sequence of operations in the closed-loop circuit.
TE
MP
ER
AT
UR
E
ENTROPY
WATER
THERMAL
OIL
THERMAL OIL
Evaporator
Pump
Condenser
WATER
Regenerator
Generator
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ORC Cycle The split system Typical applications New solutions
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5
Thermal
power from
thermal oil
100 %
18 %Net electric power
3 % Thermal losses
(insulation, generator)
79 %
Thermal
power to
heat users
Overall Thermal Efficiency: about 97 %D
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ORC Cycle The split system Typical applications New solutions
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• High cycle efficiency
• Very high turbine efficiency (up
to 85 %)
• 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, due to
the absence of moisture in
the vapour nozzles
ORC technical advantages
• Simple start-stop procedures
• Automatic and continuous
operation
• No operator attendance needed
• Quiet operation
• Very High Availability (Admont –
over 50,000 hours of operation,
availability > 98%)
• Partial load operation down to
10% of nominal power
• High efficiency also at partial
load
• Low O&M requirements: about
3-5 hours / week
• Long life
Operational advantages / results
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ORC Cycle The split system Typical applications New solutions
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T600 unit (600 kWel) lay-out
Lay–out: one single skid up to 800 kWel
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ORC Cycle The split system Typical applications New solutions
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T1500 unit (1500 kWel) lay-out
Lay–out: separate items above 800 kWel
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The split systemD
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ORC Cycle The split system Typical applications New solutions
• Additional feeding of thermal oil power on lower temperature
level (feeding/return temp. 250/130°C)
• Additional thermal oil power available is dependent on humidity
of used biomass (no replacement of air pre-heater)
• Higher electrical plant efficiency (generated electric power /
biomass fuel power)
• Additional thermal oil economizer, piping, pump, 3way valve and
heat exchanger thermal oil/working fluid necessary
Rationale:
Residual heat power from exhaust gases can be used for
additional pre-heating of the organic fluid of the ORC unit,
instead of water heating.
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ORC Cycle The split system Typical applications New solutions
The split system
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Combined Heat & Power (CHP) with SplitStandard Sizes
T200-CHP
Split
T500-CHP
Split
T600-CHP
Split
T800-CHP
Split
T1100-CHP
Split
T1500-CHP
Split
T2000-CHP
Split
Heat Source Thermal oil Thermal oil Thermal oil Thermal oil Thermal oil Thermal oil Thermal oil
Nominal
temperature “HT”
loop (In/out)
315/250°C 315/250°C 315/250°C 315/250°C 315/250°C 315/255°C 315/255°C
Thermal power
input “HT” loop
1200 kW 2900 kW 3500 kW 4600 kW 6000 kW 8700 kW 10700 kW
Nominal
temperature “LT”
loop (in/out)
250/150°C 250/150°C 250/150°C 250/150°C 250/150°C 255/155°C 255/155°C
Thermal power
input “LT” loop
140 kW 340 kW 410 kW 540 kW 715 kW 1090 kW 1320 kW
Hot water
temperature
(in/out)
60/80°C 60/80°C 60/80°C 60/80°C 60/80°C 60/90°C 65/95°C
Thermal power to
the cooling water
circuit
1090 kW 2600 kW 3150 kW 4100 kW 5370 kW 7950 kW 9815 kW
Net active electric
power output
218 kW 570 kW 680 kW 940 kW 1220 kW 1675 kW 2005 kW
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Company profile: today
• 69 units in operation for a total
installed power of ca. 65.000 kW
• 33 units under construction
• Production capacity: ca. 35units / year
(updated 31/12/2007)
T500T600T800T1100T1500T2000
GeothermalU
nder
con
stru
ctio
n
Ope
ratin
g
2 1311
5 106 146 18
1HR15
11
1
2
5 T200
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Fuels
• Wood biomass: sawdust,
woodchips, bark, treated wood
• Other biomass (dried sewage
sludge, straw, green cuttings,
rice husk, etc.)
• Waste material
Biomass CHP – Fuels & Heat consumers
Heat Consumers
• Air pre-heating in MDF industries
• Timber drying in sawmills
• Saw dust drying in wood pellet
factories
• District heating networks
• Refrigeration
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ORC application in Sawmills
trunks selecting barking
dryingdryingpackaging product
processing
Biomass powered
boilerORC
thermal
oilelectric
power
hot
water
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CHP – Applications: Sawmills
Selected reference Plants
Sawmill Theurl - (Tyrol, Austria): T1100-CHP – 2004
Sawmill Schwaiger (Hengersberg, Germany): T1500-CHP – 2005
Sawmill Mayr-Melnhof (Leoben, Austria): 3*T1500-CHP – 2005
Holzwerke Gmach (Pösing, Germany): T1500-CHP – 2005
Holzwerk Weinzierl (Vilshofen-Alkofen, Germany): T1500-CHP – 2005
Sawmill Templin (Templin, Germany): T600-CHP – 2005
Sawmill Echtle (Nordrach, Germany): T800-CHP - 2006
Sawmills Ludwig Ziegler (Plössberg, Germany): T1500-CHP – 2006
Holzindustrie Pfeifer (Imst, Austria): T800-CHP – 2006
Sawmill Anteholz (Bromskirchen-Somplar, Germany): T1500-CHP - 2007
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Application in Pellet production
Biomass powered
boilerORC
thermal
oilhot
water
electric
power
UR < 13 %
trunks barking chipping
wood
chips
selection/
sorting
suitable granulometry;
UR around 40 %drying
pellet making
press
dedusting/
selection/
refiningpellets
air cooling/
dedusting
pellets ready to
be packaged
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CHP – Applications: Pellet Industry
Selected reference Plants
Erdenwerk Gregor Ziegler (Plössberg, Germany): T1100-CHP – 2003
Schachl Holzindustrie (Abtenau, Austria): T1100-CHP – 2004
Pabst Holzindustrie (Obdach, Austria): T1500-CHP – 2005
Sawmill Mayr-Melnhof (Leoben, Austria): 3*1500-CHP – 2005
Bio-energie Mudau (Mudau, Germany): T1100-CHP – 2006
Erdenwerk Gregor Ziegler (Plössberg, Germany): T2000-CHP - 2007
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CHP – District heating networksSelected Reference Plants Divided per type of network
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New networks Biomass:
Biere, Switzerland: HER 300 – 1998
Stadtwärme Lienz (Lienz, Austria): HER 1000 – 2001
Stadtwerke Neckarsulm (Neckarsulm, Germany): T1100 – 2003
Tiroler Wasserkraft AG (Längenfeld, Austria): T1100-CHP – 2004
Biomasseheizkraftwerk (Hall, Austria): T1100-CHP – 2005
Trhovè Sviny, Czech Republic: T600-CHP – 2005
Holzwärme (Altenmarkt, Austria): T600-CHP – 2005
Biomasse Heizanlage Bad Staffelstein (Bad Staffelstein, Germany): T500-CHP – 2006
ORC Cycle The split system Typical applications New solutions
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CHP – District heating networksSelected Reference Plants Divided per type of network
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Existing networks Biomass:
T.C.V.V.V. (Tirano, Italy): T1100-CHP – 2002
Fernheizwerk Toblach (Dobbiaco, Italy): T1500-CHP – 2003
Hackschnitzel und Heizgenossenschaft (Lofer, Austria): T600-CHP – 2004
Hackschnitzel und Heizgenossenschaft (Grossarl, Austria): T600-CHP – 2004
Stadtwärme Lienz (Lienz, Austria): T1500-CHP – 2005
Biothermie (Altötting, Germany): T800-CHP – 2005
Fernwärmeversorgungs - GmbH Tamsweg (Tamsweg, Austria): T600-CHP – 2006
Stadtwerke Rheinsberg GmbH (Rheinsberg, Germany): T600-CHP – 2007
ORC Cycle The split system Typical applications New solutions
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CHP – District heating networksSelected Reference Plants Divided per type of network
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Existing networks Fossil Fuel:
Alternative Energie Salzburg (Siezenheim, Austria) : T1500 – CHP
Holzheizkraftwerk Oerlinghausen (Oerlinghausen , Germany): T600 – CHP – 2006
Biomasse Wärmeverbund Aichach (Aichach, Germany): T800-CHP – 2007
Bio-Heizkraftwerk Ludwigsfelde (Ludwigsfelde , Germany) : T1500 – CHP – 2007
OZC (Ostrow , Poland) : T1500 – CHP - 2007
ORC Cycle The split system Typical applications New solutions
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New technical solutions and applications
a) Heat recovery from IC Engines (Biogas, Landfill gas, Bio oil,
Syngas, natural gas)
b) Steel, Cements, Glass ovens exhaust gas
c) Gas turbine exhaust gas
d) Any waste hot gas flow
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Heat Recovery from IC Engines: up to 10% additional electric power
INTERNAL COMBUSTION ENGINE
EXHAUST
GASHEAT RECOVERY SYSTEM
Tin Water Tout Water
ELECTRIC POWER
COOLING SYSTEM
(DRY OR WET)
Company Profile ORC Cycle Advantages / Solutions Applications
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Heat Recovery from IC Engines: Reference plants under construction
Company Profile ORC Cycle Advantages / Solutions Applications
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Pisticci (Italy) – 1740 kWel from 3 Wartsila 18V32 Engines (3 x 8 MWel),
Flue gas temperature : ca. 350 °C
Molfetta (Italy) – 580 kWel from 1 Wartsila 18V32 Engine (8 MWel),
Flue gas temperature : ca. 350 °C
Pavia (Italy) – 490 kWel from 1 MAN Engine (8,3 MWel)
Flue gas temperature : ca. 315 °C
Portogruaro (Italy) – 500 kWel from Wartsila 18V32 Engine (7 MWel)
Flue gas temperature : ca. 350 °C
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Heat Recovery from IC Engines: Application in CHP Applications
Company Profile ORC Cycle Advantages / Solutions Applications
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In case thermal power (hot water) is valuable (users of
hot water are available), it is possible to optimize the design of the ORC cycle downstream for cogeneration (CHP).
Results:
• the electric power output decreases somewhat,
• the overall efficiency of the system improves greatly
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Heat Recovery from IC Engines: Application in CHP Applications
Company Profile ORC Cycle Advantages / Solutions Applications
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Reference plant under construction
Hamburg (Germany) – 190 kWel
Heat recovery : 3 ABC 8DZC-1000 Engines (3 x 1,4 MWel))
Flue gas temperature : ca. 375 °C
Hot water for CHP : 55/75°C
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MIROM – Retrofit heat recovery from pressurized water boiler in waste incinerator - Roeselare (Belgium)
(started-up beginning of April 2008)
• Heat source: hot water at 180°C (return at 140°C)
• Cooling: water / air
• Electric power: 3 MW
• Net electrical efficiency: 16,5%
Company Profile ORC Cycle Advantages / Solutions Applications
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Via Cernaia, 10 - 25124 Brescia - Italy
Visit our web site: www.turboden.it
E-mail: [email protected]
Phone: +39.030.3552001
Fax: +39.030.3552011
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Thank you for your attention