ORC - Organic Rankine Cycle technology for biomass and EfW cogeneration and trigeneration

Carlo Minini – Sales and Business Development Manager Oceania

Bioenergy Australia Conference 2015 Launceston, November 30th

member member

ORC - Organic Rankine Cycle technology for biomass and EfW cogeneration and trigeneration

Ref.: 15-COM.P-23-rev.0

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About Us

Turboden is a leading European company in development and production of ORC(Organic Rankine Cycle) turbogenerators. This state of the art equipment generatesheat and power from renewable sources and heat recovery in industrial processes.

The company was founded in 1980 in Milan by Mario Gaia, Associate Professor atPolitecnico di Milano, teaching Thermodynamics, Renewable Energy and specificallystudying ORC systems. At present Prof. Gaia is Honorary Chairman. A number of hisformer students are key persons in the Company and the whole Company ispermeated by innovative and research oriented spirit.

Turboden has always had a single mission: to design ORC turbogenerators for theproduction of heat and electrical power from renewable sources, while constantlystriving to implement ORC technical solutions.

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1984 – 40 kWe ORC turbo-generator for a solar plant in Australia

1987 – 3 kWe ORC turbo- generator for a biomass plant in Italy

2008 – 3 MWe ORC turbo-generator for heat recovery on a waste incinerator in Belgium

1988 – 200 kWe ORC geothermal plant in Zambia

2009 – First 100 plants and first installed 100 MWe

2010 – First plant overseas

2015 – Over 300 ORC plants in the world and back to Australia!

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Experience

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260 biomass projects in 30 countries (5 CCHP)9 Waste to Energy projects in 6 countries

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• standard units from 200 kWe to 10 MWe

• customized solutions up to 30 MWe

electricity

heat

Biomass

Heat recovery

Geothermal

Solar

Turboden designs and develops turbogenerators based on theOrganic Rankine Cycle (ORC), a technology for the combinedgeneration of heat and electrical power from various renewablesources, particularly suitable for distributed generation

Waste to energy

“fuel”

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What We Do

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Water

Small, fast moving molecules

Metal parts and blade erosion

Multistage turbine and high

speed with mechanical stress

High molecular mass fluid

Large flow rate

Larger diameter turbine with high

efficiency of the turbine (85-90%)

Slow rotation speed and few stages (2-5)

No wear of blades and metal parts

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Water vs High Molecular Mass - Working Fluid

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Steam Rankine Cycle

Tem

per

atu

reEntropy

Tem

per

atu

re

Entropy

Organic Rankine Cycle (ORC)

• High enthalpy drop• Superheating needed• Risk of blade erosion

• Small enthalpy drop• No need to superheat• No supercritical pressure• No risk of blade erosion

Thermodynamic features and

consequences

• Water treatment required• Highly skilled personnel needed• High pressures and temperatures in the cycle

• Non-oxidizing working fluid with no corrosion issues• Minimal personnel and O&M (1)

• Completely automatic (2)

• No blow down

Operation and maintenance

costs

• Convenient for large plants and high temp• Low flexibility with significantly lower

performances at partial load

• High flexibility and good performances at partial load• High availability (average >98%)• Possibility to work at low temperatures (90+°C)

(1) Standard maintenance: 2-3 days per year(2) Fast start-stop procedure (ca. 20 min), partial load operation (down to 10% of nominal load)

Other features

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ORC provides significant advantages as compared to steam

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ORC finds many applications in the Waste to Energy sector

Steam or hot water from incinerator boiler

1. Revamping of existing WTE plants

2. New units

Municipal Solid Waste gasification

Landfill engines exhaust gas

Primary heat conversion system - alternative to steam turbine

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A

B

C

D

Energy can

neither be

created nor

destroyed, but it

can be wasted

’’

‘‘

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Heat sourceTurbo

expanderHeat

exchangers

Heat rejection system

Municipal solid waste incineration

Landfill gas Waste syngas Hot stream in WTE Other

Heat carrier loop:• Pressurized water• Saturated steam• Thermal oil1

Direct Exchange1

Electric power (or mechanical)

Cooling tower Water cooled condenser Air cooled condenser …

Potential thermal users: Process District heating Absorption chiller …

Organic Rankine Cycle Steam Rankine Cycle Other

Waste to Energy - General scheme

Flue gas cleaning

Note: 1) to be evaluated depending on exhaust gases composition

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Waste to Energy applications

Steam or hot water from incinerator/boiler

1. Bunker2. Furnace3. Heat recovery Steam generator3a. Economizer3b. District Heating Network

3c. ORC4a. ESP4b. Chemical Reactor4c. Bag Filter4d. Denox5. Chimney

3b

1. in existing plant as second user to existing district heating network2. for new installation also in power only configuration

A

34a

3a

2

1

4b 4c

4d

5

3c

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Plant type: 62,000 t/yr MSW plant, in operation since 19762 boilers of 8 MW each

Customer: MIROM

In operation since: April 2008

Heat source: hot water at 180°C (back 140°C)

Cooling source: water/air dissipation

Total electric power: 3 MW

Net electric efficiency: 16.5%

Availability: > 98%

• Example of Turboden 30 HR ORC plant for heat recovery from district heating waste to energy plant:

3 MWe installation in Roselare (Belgium)

• Good performance in a very fluctuating conditions

• Plant overall efficiency increased

Use of heat: hot water at 180°C

1. District heating from 1986: 21 customers, 7.5 km network

2. ORC from 2008, in parallel to district heating use


Hot water from WTEA

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Mirom, Belgium

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Plant type:Heat recovery from pressurized water boiler in waste incinerator:• 2 lines of 9.5 t/h 150,000 t/yr• Production of superheated water at 200°C

130 GWh/yr to district heating, ORC in parallel

Customer: Seche Environnement Usine – Alcea(Nantes - France)

In operation since: October 2014

Heat source: hot water at 200°C (back 130°C)

Cooling source: water/air

Total electric power: 2.7 MW

Net electric efficiency: 16.5%Example of Turboden 30 HR Low temperature ORC plant for heat recovery from hot water: 2.7 MWe installation in Nantes (France)


Hot water from WTEA

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Nantes, France

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Plant type:Heat recovery from low pressure steam in waste incinerator: • 5 t/h grate furnace of (PCI = 2200 kcal/kg)• Recovery boiler: 14 t/h steam at 350°C, 29.5 bar• Back pressure turbine of 1MW• District heating fed by steam at 4 bar with a 7 MW steam

exchanger hot water boiler

End user: UVE du SYDOM (operated by VEOLIA propreté RhinRhone) – Lons le Saunier, France

In operation since: August 2015

Heat source: low pressure steam at 4.5 bar 180°C (back 78°C)

Cooling source: air

Total electric power: 750 kW


Low-pressure steamA

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Lons le Saunier, France

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Internal combustion engine

Syngas combustion boiler

Syngas Turbine

Heat exchanger Direct Exchange Thermal oil

Mechanical/electric power

Cooling tower Water cooled condenser Air cooled condenser

Organic Rankine Cycle25 ÷ 35% additional power(1)

Note: 1) Percent of the prime mover nominal power referring to gas turbines

Municipal Solid Waste gasifier + syngas cleaning

Municipal Solid Waste gasificationB

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http://www.google.it/url?url=http://www.directindustry.com/prod/heatcraft-europe-friga-bohn-hk-refrigeration/air-cooled-condensers-8259-1292685.html&rct=j&frm=1&q=&esrc=s&sa=U&ei=50akU4fzKqGAywOg8IHYDg&ved=0CC4Q9QEwDDgo&sig2=GrwCMdy41rOrJS3d5LhDJQ&usg=AFQjCNHj_GybUmmJrZ0lADnekjKTWbudUg


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Plant type:Industrial waste synthesis gas burned in a thermal oil boiler

Customer: ITC-KA Enerji Uretim Sanayi VE TicaretA.S., Mamak (Ankara), Turkey

Started up in: 2014 and 2015

Heat source: thermal oil at 315°C from 2 boilers of 20 MWt each

Cooling source: cooling towers

Total electric power: 2 ORC units of 5.5 MWe each

Net electric efficiency: 25%

Availability: > 98%

Example of Turboden tailor-made ORC plant for heat recovery from waste gasification: 5.5 MWe installation in Ankara (Turkey)

Syngas combustion exhaustsB

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Ankara, Turkey

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Internal combustion engine

Heat exchanger Direct Exchange Thermal oil

Mechanical/electric power

Cooling tower Water cooled condenser Air cooled condenser

Organic Rankine Cycle7 ÷ 10% additional power(1)

Note: 1) Percent of the prime mover nominal power

Landfill gasification

Landfill engines exhaust gas C

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Plant type:15MW engine power plant utilizing landfill gas (one of the largest facilities in Europe) 49,000 t/yr of biowaste composting

Customer: Helsinki Region Environmental Services Authority (HSY)

In operation since: October 2011

Heat source: thermal oil at 275°C from 4 MWM engines of 4 MWe each

Cooling source: air coolers

ORC electric power: 1.3 MW


Availability: > 98%

Example of Turboden 14 HR ORC plant for heat recovery from landfill gasification: 1.3 MWe installation in Espoo (Finland)

Landfill gas feed enginesC

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Helsinki, Finland

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Steam ORC

Working fluid temperature > 400°C 100 - 320°C

Working fluid pressure > 30 bar < 15 bar

Flexibility Low High

Operators needed At least 1 licensed operator 24/7 1 low-skilled 1 hour/day

Water treatment necessary not present

Turbine overhaul and/or replacement 5 – 7 years 20 years

Gross Electric Efficiency 20 – 30% 18 - 26%

Primary heat conversion system alternative to steam turbineD

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Ph

oto

: co

urt

esy

of

Alb

any

Co

un

ty S

ewag

e D

istr

ict

Plant type: Heat recovery from dried sewage sludge incineration(Sewer District water treatment plant)

End user: Albany County Sewer District

Site: Albany County, Menands, NY

Start-up in operation since March 2013

ORC electric power: 0.9 MW

Heat source: thermal oil at 285°C

Electrical efficiency: 19.3%

Cooling source: water/air dissipation

Dried sludge incinerationD

Multiple-hearth incineration for sewage-sludge produced in a 35 million gallon per day waste water treatment plant

Operation: 106 hours/week

1.5 dry tons per hour of sewage sludge

Exhaust gas from sludge incinerators: 538 - 677 °C

Incinerator flue gas volumetric flow rate: 17 ton/sec– 21 ton/sec

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Menands, US

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CCHP – Combined Cooling Heating Power

coldwater

ABSORPTION CHILLER

hotwater

ELECTRIC POWER

DISTRICT HEATING

coldwater

COOLING SYSTEM

BIOMASS POWERED

BOILER

BIOMASS

ORC

Thermaloil

USE IN PUBLIC

BUILDINGS, HOTELS, …

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Hybrid Biomass/PV CCHP Reference Project

Client: Polytechnik for L’OREAL

Start-up: October 2014

Heat source: forestry and sawmill residues

Temperature: thermal oil at 312°C

Water temperature (in/out): 75/90°C

ORC electric power: 600 KW

Net electrical efficiency: 18%

Burgos, Spain

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Waste Biomass Reference Project

Client: Morton Seed and Grain / Unigrain

Start-up: September 2015

Heat source: oat husks

Temperature: 23 bar saturated steam

Water temperature (in/out): 27.5 - 38°C

Max electric power: 600 KW

Net electrical efficiency: 17%

Project description: The plant will convert between 6,000 and 10,000 tons of oat husk per year.The Turboden 6 HR ORC unit is fed with saturated steam instead of the traditional thermal oil and will be used at part load (60-80%) most of the time for a couple of years, taking advantage of its ability to follow variable loads and retain high part-load efficiency (e.g. at 50% load, around 90% of the nominal load efficiency).

Wagin, Western Australia

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Conclusions

Happy to answer your questions…

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Back-up Slides

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ORC Partial Load Efficiency

One of the key

points in the

success of ORC

technology is the

capability to

adapt to load

variation easily

and quickly

’’

‘‘

Actual Load / Nominal Load

Part load operation down to 10% of nominal load.

Mantains 90% of cycleefficiency at 50% of load

Turboden ORC units automaticallyadapt the cycle at the ambient temperature variations

OR

C A

ctu

alEf

fici

ency

/ O

RC

No

min

alEf

fici

ency

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Flexible and automatic

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Technology Pros Cons

Internal combustion engine • High conversion efficiency• Syngas cleaning system required• Frequent maintenance

Syngas turbines • Good reliability• Medium conversion efficiency• Few references

Syngas combustion boiler• Simplicity• Lower O&M costs

• Lower conversion efficiency

Municipal Solid Waste gasificationB

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Case study: off-setting site own consumption (1/2)

Client: To be announced later (Sawmill)Site: Western Canada

Project description: Biomass: waste of timber production. Existing biomass furnace and thermal oil system (spare capacity available)ORC Unit: Turboden 22 HRStatus: prospectElectric power generated: 2 MW to off-set the sawmill own consumptionKey driver of the project:• Reducing plant operating costs (energy) with no additional

personnel utilizing spare capacity of existing furnace and thermal oil system

• Reduced Capex

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Project featuresExisting biomass furnace and thermal oil system (spare capacity available)

Biomass Fuel Sawmill waste wood

ORC unit proposed Turboden 22 HR

Electric power output (net)

2000 kW

ORC electric efficiency ~ 20%

Biomass consumption ~ 5 ton/h

Cooling water temperature (in/out)

25/35°C

Annual operating hours 8000

Electricity price sensitivity analysis

Amount of investment estimation

Complete ORC installed (incl. ACC) USD 3.4M

BoP (engineering, civil works, contingencies) USD 800k

Overall CAPEX USD 4.2M

OPEX (ORC - BoP O&M) USD 80k

WACC 7%

Electricityprice (c$/kWh)

Cash flow (M$)

PBT (yr) IRR 15yrNVP 15yr

(M$)13 2.00 2.4 47.5% 14.0

12 1.84 2.6 43.6% 12.6

11 1.68 2.8 39.7% 11.1

10 1.52 3.2 35.8% 9.6

9 1.36 3.6 31.9% 8.2

8 1.20 4.2 27.9% 6.7

7 1.04 4.9 23.7% 5.3

6 0.88 6.0 19.5% 3.8

Case study: off-setting site own consumption (2/2)

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• EXPERIENCE

• GUARANTEES

• HIGH AVAILABILITY

• REMOTELY CONTROLLED

• FULLY AUTOMATIC

• UNATTENDED

• LOADS FLEXIBILITY

• NO WATER

• MODULAR EXPANSION

PEACE OF MIND

So, what do we really offer?