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Turboden ORC plants for Industrial Heat RecoveryThe proven way to address environmental sustainability
Codice doc. 11-COM.P-9-rev.3
Update: 1/04/2011
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About us – A Pratt & Whitney Power Systems Company
Research
Center
Hamilton
Sundstrand
Pratt & Whitney
SikorskyUTC Power OtisCarrierUTC
Fire & Security
Fortune 50 corporation$52.9B in 2009 sales
180 countries206,700 employees
Large
Engines
Small
Engines
After
marketMarine
Mobile
Power
Heat to Electricity
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Pratt & Whitney, a division of United Technologies Corporation (UTC), is a
world leader in the design, manufacture and service of aircraft engines,
industrial gas turbines and space propulsion systems.
Pratt & Whitney Power Systems (PWPS), the industrial gas turbine business
of Pratt & Whitney, provides power generation and mechanical drive solutions
for the electric generation, oil and gas markets, including service through the
entire product life cycle
PWPS also manufactures and markets the PureCycle® system that can
harness heat in the form of hot water from many different sources such as
geothermal or oil & gas co-produced fluids, reciprocating engines, and
industrial waste heat to generate clean and reliable electricity.
Turboden, a Pratt & Whitney Power Systems company, is a European leader
in ORC technology for the generation and cogeneration of heat and power from
renewable energy and heat recovery.
• operating profit of $1.99 billion in 2010
• revenues of $12.94 billion
• 36,000 employees
• more than 11,000 customers
• 195 countries
About us – A Pratt & Whitney Power Systems Company
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Turboden – What We Do
•standard size Turbogenerators from 200 kWel to 3 MWel
• customized products up to 15 MWel
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.
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Turboden - 30 Years of Experience
1984: A 40 kWel ORC turbogenerator for a
solar application in Perth, Australia
1987: A 3 kWel CHP biomass ORC turbo-
generator plant in Milan
2008: A 3 MWel ORC turbogenerator for waste heat in Belgium
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The Turboden ORC Turbogenerator
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ORC is a commercial
technology for
distributed production
of combined heat and
power from various
renewable energy
sources
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The Thermodynamic Principle: The ORC Cycle
TE
MP
ER
AT
UR
E
ENTROPY
WATER
THERMAL
OIL
THERMAL OIL
Evaporator
Pump
Condenser
WATER
Regenerator
Generator
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 vapor powers the turbine (4 5), which is directly coupled to the
electric generator through an elastic coupling. The exhaust vapor flows through the regenerator (5 9) where it
heats the organic liquid (2 8). The vapor 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.
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Advantages of Turboden ORC Turbogenerators
Technical advantages
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, 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
Very High Availability (Admont – over
50,000 hours of operation, availability >
98%)
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
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Layout – Some Examples
TURBODEN 7 layout
TURBODEN 18 layout
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Layout – Some Examples
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ORC Applications – Heat Recovery
Heat Recovery
Turboden ORCs can produce electricity by recovering heat from
industrial processes, reciprocating engines and gas turbines.
The power of Turboden Turbogenerators in this application
generally ranges between 400 kW and 5 MW electric.
Biomass Heat Recovery Geothermal Solar Thermal
Power
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HR – Applications / Energy Sources
Internal combustion engines exhaust gas (ORC as bottom
cycle to Diesel and gas reciprocating engines, gas turbines)
Steel furnaces exhaust gas
Cement, Glass and other non ferrous materials furnaces
exhaust gas
Exhaust Gas from waste incineration (civil/industrial)
Gaseous sources:
Liquid sources:
Condensing
sources:
Refineries hot streams
Cooling water (or other fluids) loops in industrial
processes
Jacket cooling water of reciprocating engines
Refineries organic vapours to be condensed
Surplus steam from production process (i.e. paper
production process)
Steam from cooling loops in industrial processes (i.e.
steel)
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HR (Heat Recovery) modules
Standard Sizes and Typical Performances
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Modules with power outputs above 3 MW are optimised case by case
TURBODEN
6 HR
TURBODEN
7 HR
TURBODEN
10 HR
TURBODEN
14 HR
TURBODEN
18 HR
TURBODEN
22 HR
INPUT - Thermal oil
Thermal oil nominal
temperature (in/out)°C 260 / 150 270 / 150 270 / 150 275 / 150 280 / 150 280 / 150
Thermal power input kW 2.970 3.600 4.880 6.700 9.000 11.400
OUTPUT - Cooling water
Cooling water temperature
(in/out)°C
25 / 35 25 / 35 25 / 35 25 / 38 25 / 40 25 / 44
Thermal power to the
cooling water kW 2.340 2.840 3.840 5.275 7.065 9.000
Performances
Gross electric power kW 600 726 1.000 1.370 1.848 2.296
Gross electric efficiency 20,2% 20,2% 20,5% 20,4% 20,5% 20,1%
Captive power consumption kW 25 30 38 52 60 76
Net active electric power
output kW 575 696 962 1.318 1.788 2.220
Net electric efficiency 19,4% 19,3% 19,7% 19,7% 19,9% 19,5%
Electrical generator
asynch., 3
phase, L.V.
asynch., 3
phase, L.V.
asynch., 3
phase, L.V.
asynch., 3
phase, L.V.
asynch., 3
phase, L.V.
asynch., 3
phase, L.V.
m 15 X 3 X 3,1 15 X 3 X 3,1 15 X 6 X 3,3 13 X 6 X 6,2 15 X 7 X 5 17 X 7 X 5
Single skid Single skid Single skid Multiple skid Multiple skid Multiple skidSize of plant
*Data indicated could change taking into account the actual features of the specific project (optimization of heat recovery application).
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Heat recovery from Internal Combustion
Engines: heat sources
Exhaust gas: Typically contains between 1/4 and 1/3 of the fuel heat, being released at relatively high temperatures (300 500 C).
ORC production reaches up to 10% of engine power output
Jacket water: very low temperature heat (< 100 C) is released by this loop to atmosphere.ORC production (including main plant savings) reaches up to 3 % of engine power output
Turboden's ORC modules for heat recovery have a power output between 400 kWe up to 10 MWe: the minimum thermal power necessary to employ a Turboden ORC is approximately 2 MWt
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Project ORC Module Site Engines
Pisticci I TURBODEN 18 HR SPLIT (1,8 MWe)In operation since IV quarter 2010
Pisticci (I) 3 x 8 MWe Wartsila Diesel engines
Oxon TURBODEN 6 HR SPLIT (0,6 MWe)In operation since IV quarter 2008
Pavia (I) 1 x 8 MWe MAN Diesel engine
FinPower TURBODEN 6 HR DIR. EXCH. (0,6 MWe)In operation since II quarter 2009
Visano (I) 1 x 17 MWe Wartsila Diesel engine
Pisticci II TURBODEN 40 HR SPLIT (3,8 MWe)Under construction
Pisticci (I) 3 x 17 MWe Wartsila Diesel engines
Cereal Docks TURBODEN 6 HR DIR. EXCH. (0,6 MWe)Under construction
Portogruaro (I) 1 x 7 MWe Wartsila Diesel engine
Eukrasia TURBODEN 6 HR SPLIT (0,6 MWe)In operation since II quarter 2010
Catania (I)2 x 1 MWe JGS/GE gas engine + 3 x 0,8 MWe JGS/GE gas engine + 1 x 0,6 MWe JGS/GE gas engine
Blue TowerTURBODEN 6 HR (0,6 MWe)Under construction
Herten (D) 2 x 2,1 MWe MWM gas engine(+ additional heat from the process)
UlmTURBODEN 10 HR cogenerative (1 MWe)Under construction
Senden (D) 2 x 2 JGS/GE gas engine(+ additional heat from the process)
KempenTURBODEN 6 HR cogenerative (0,6 MWe)Under construction
Kempen (D) Diesel engine
MondopowerTURBODEN 10 HR (1 MWe)Under construction
Chivasso (I) 1 x 17 MWe Wartsila Diesel engine
HSY TURBODEN 14 HR (1,3 MWe)Under construction
Ämmässuo (FIN) 4 x 4 MWe MWM gas engines
Heat Recovery from Internal Combustion
Engines: reference projects
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Heat Recovery from Gas Turbine: 20% add’l
power / reduction in specific emissions
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Centaur 40 Solar
SGT-200 Siemens
Mars 100 SolarTitan 130 Solar
LM2500 GEFT 8 P&W
UGT 25000 ZoyraRB211 RR
0%
10%
20%
30%
40%
50%
60%
70%
80%
0
1.000
2.000
3.000
4.000
5.000
6.000
7.000
8.000
9.000
0 5.000 10.000 15.000 20.000 25.000 30.000
OR
C G
ross
Po
we
r O
utp
ut
[kW
]
Gas Turbine Shaft Power Output [kW]
TURBODEN ORCs Power output vs Gas Turbine Shaft Power Output
Pel ORC % Pel ORC/Pel Gas Turbine
SGT-500 Siemens
SGT-700 Siemens
ORC suitable for heat recovery in:
Remote/unmanned locations with variable operating loads (e.g. gas compressor stations)
“Peak load” power stations (easy and fast start-up procedures)
Heavy duty / continuous applications
NOTE: Indicative values assuming ambient air temperature of 15°C, Gas Turbines operating at nominal load;
calculations based on Gas Turbine exhaust gas properties as reported in specific suppliers web sites.
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Reference Case Study:
Heat recovery from Solar CENTAUR gas turbine in a Gas
Compressor station in Canada
Gas Turbine prime power: 3.5 MWe
Gas Turbine efficiency: 28%
ORC electric power: 1MWe
General Contractor: IST (Innovative Steam Technologies)
Final Client: TransGas
Under construction, start up 1st quarter 2011
Heat Recovery from Gas Turbine
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Heat Recovery In Cement Production Process
Exhaust gas streams from
cement production
process:
Kiln pre-heater gas
Clinker cooler gas
Main Exhaust Gas
Characteristics:
High dust content
Different operating conditions
depending on mill operation,
season, plant upsets, etc.
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Heat Recovery In Cement Production Process
Reference Case study: PRS gas waste heat recovery
Clinker production capacity: ≈ 5.000 ton/day
Heat source: exhaust gas @ 330°C
Gas cooled down to 220°C (extra heat used for raw
material pre heating)
ORC electric power: ca. 2 MWe
Client: CIMAR – ITALCEMENTI GROUP (Morocco)
In operation since 2nd quarter 2010
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Heat Recovery In Refractory Production Process
Reference Case study: Refractory ovens exhaust
gas heat recovery
Refractory production capacity: ≈ 250 ton/day
Heat source: exhaust gas @ 500 °C
Gas cooled down to ca. 150 °C
ORC electric power: ca. 1 MWe
Client: RHI GROUP (Radenthein - Austria)
In operation since: first quarter 2009
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Heat Recovery in Steel Industry
Rolling, forging
Strip processing
Heat treatment
BOF
Blast furnaces
Sinter
Electric Arc Furnace
Main exhaust gas streams available:
Relatively clean exhaust gas at moderate
temperature
Cost effective for ORC ≥ 600/800 kWe
Exhaust gas: high flows, high temperatures,
high dust content, large variations in operating
cycle, environmental constraints
Interface between process and energy
recovery unit is critical
ORCs proposed where heat recovery
exchangers are available
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Heat Recovery in Glass Industry
High exhaust gas temperature
Constant operating conditions
Exhaust gas with moderate dust content
Exhaust gas must be cooled not below 200°C
Heat source main properties:
High temperature ORC cycle employed:
ORC electrical efficiency up to 25 %
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Heat Recovery In Glass Production Process
Reference Case study: Float glass production process
Glass production capacity: ≈ 600 ton/day
Heat source: exhaust gas at approximately 500°C
ORC electric power: ca. 1,3 MWe
Final Client: AGC Glass Europe – Cuneo Plant
General contractor: GEA Bischoff
Under construction, start up 4nd quarter 2011
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Heat Recovery from Hot Liquid streams
Thermal power in hot liquids streams can be used
directly as input to the ORC unit
Cost-effective plants with ORC power greater than
1.000 kWe and liquid temperature higher than 100-120 °C
Solutions studied and optimised case-by-case.
Power Output > 1 MWe:
Turboden tailor made
ORC plants
Power Output < 1 MWe
Pratt and Whitney
PureCycle®
Modular/scalable 270 kWe ORC unit: PureCycle®
Cost-effective plants starting from single 270 kWe
PureCycle® unit (reduced investment costs)
Three standard cycles to match heat sources
(water, etc.) temperatures between 90 °C and 150 °C
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Heat Recovery – Reference Case study
Plant type:
Heat recovery from pressurized
water boiler in waste incinerator
Customer :
MIROM (Roeselare-Belgium)
In operation since:
2nd quarter 2008
Heat source:
hot water at 180 C (back 140 C)
Cooling source:
water/air
Total electric power:
3 MWel
Net electric efficiency: 16,5%
Availability: > 98%
Example of Turboden tailor-made ORC plant for heat
recovery from hot water: 3 MWe installation in Roeselare (B)
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The PureCycle® Power System
• 280 kW Gross Power
• Free fuel
• Zero emissions
• Renewable baseload power generation
• 195°F – 300°F resource range
• Modular and scalable for larger plants
• Short lead times
• 24/7/365 remote monitoring
• High availability
* 91ºC – 149ºC
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Cooling Tower
• Commissioned December 2008
• Operating on jacket water of 10MW reciprocating engine ~ 200kW net
• Displaces expensive fuel costs
• Supports green initiative of customer
Heat Recovery – Reference Example
Example of PureCycle® unit in operation: heat recovery
from reciprocating engine in Guatemala
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Heat Recovery Data Collection Sheet
Title: Heat recovery data collection sheet
Date: ………………………
Company: …………………………………………………………………………………………
Reference person: …………………………………………………………………………….
e-mail ……………………………………….. tel. ……………………….
Examined process/es: ………………………………………………………………………….
Note: (*) data are mandatory for a preliminary evaluation
Technical data:
(*)T-1Heat Source: Liquid Gas
(*)T-2Temperature:
………
….. °C
(*)T-3Flow rate:
………
….. kg/s ………………………. Nm3/hr
T-4Heat source characteristics
T-4aComposition:
CO2 ………… %
CO ………… %
H2O ………… %
N2 ………… %
Other (…………) ………… %
Other (…………) ………… %
Other (…………) ………… %
T-4bdust content: ………… mg/Nm3
T-4cpresence of compounds potentially aggressive for
the heat recovery system: ……………………………………………………
T-5Minimum temperature achievable for the waste heat source …………. °C
Notes: ………………………………………………………………………………
………………………………………………………………………………
………………………………………………………………………………
………………………………………………………………………………
T-6If possible, enclose a PFD
T-7Average temperature at installation site: ……….. °C
T-8Height above sea level: ………… m
T-9Availability of cooling water (well, river, ...)
………………………………………………………………………………………….
Temperature ……….. °C
Flow rate ……….. kg/s ……….. m3/h
T-10If possible, enclose a typical daily operation diagram (flow rates and temperatures)
T-11Other notes:
………………………………………………………………………………………….
………………………………………………………………………………………….
………………………………………………………………………………………….
………………………………………………………………………………………….
………………………………………………………………………………………….
………………………………………………………………………………………….
………………………………………………………………………………………….
………………………………………………………………………………………….
………………………………………………………………………………………….
Economical data
(*)E-1Operating time: ………………….. hours/day
………………….. hours/year
E-3Energy sources:
E-3aElectricity:
Average cost: ………………….. €/MWh
E-3bMethane / natural gas:
Yearly consumption: …………………… Nm3
E-3cOther fuels: ………………………………………….
Yearly consumption: …………………… [………………]
Average cost: ………………….. [€ / …………...]
E-4Possible co-generative use:
temperatures: …………/………… °C
Additional notes: ……………………………………………..
……………………………………………..
……………………………………………..
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Turboden at a Glance
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Turboden at a Glance
R&D
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
MARKETING/SALES
Evaluation of technical
& economical feasibility
of ORC power plants
Customized proposals
to maximize economic &
environmental targets
Support for applications
to Public Authorities for
Green Power incentives
DESIGN
Complete in-house
mechanical design
Proprietary design
and own
manufacturing of ORC
optimized turbine
TOOLS
• Thermo-fluid-
dynamic programs
• FEA - Finite Element
Analysis
• 3D CAD-CAM
• Vibration analysis
SERVICE
Start-up and
commissioning
Maintenance,
technical assistance to
operation and spare
parts service
Remote monitoring &
optimization of plant
operation
OPERATION &
MANUFACTURING
Outsourced
components from
highly qualified
suppliers
Quality assurance
& Project
management
In house skid
mounting to minimize
site activities
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Turboden – Facts & Figures
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(Last update: January 2010)
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Notes
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Notes
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Notes
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Turboden s.r.l.
Via Cernaia, 10 - 25124 Brescia, Italia
tel +390303552001 - fax +390303552011
[email protected] www.turboden.it
C.F./P.I. IT02582620981
capitale sociale €1.800.000 i.v.
R.I.: C.C.I.A.A. di Brescia 02582620981
REA 461817