5 2 Bini ANG - Finance · PDF fileMolfetta (Italy) – 580 kWel from 1 Wartsila 18V32 Engine (8 MWel), Flue gas temperature : ca. 350 °C Pavia (Italy) – 490 kWel from 1 MAN Engine

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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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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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• 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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T600 unit (600 kWel) lay-out

Lay–out: one single skid up to 800 kWel

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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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• 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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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


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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


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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


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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


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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),


Pavia (Italy) – 490 kWel from 1 MAN Engine (8,3 MWel)


Portogruaro (Italy) – 500 kWel from Wartsila 18V32 Engine (7 MWel)


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Heat Recovery from IC Engines: Application in CHP 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


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Reference plant under construction

Hamburg (Germany) – 190 kWel

Heat recovery : 3 ABC 8DZC-1000 Engines (3 x 1,4 MWel))


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%


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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

Documents

5 2 Bini ANG - Finance · PDF fileMolfetta (Italy) – 580 kWel from 1 Wartsila 18V32 Engine (8 MWel), Flue gas temperature : ca. 350 °C Pavia (Italy) – 490 kWel from 1 MAN Engine