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TYPICAL ORC PRESENTATION FOR
GLASS SECTOR
Over the years, following an increasingly
360° approach and the growing
responsibilities, the company has gained
the role of EPC Contractor in prestigious
public and private projects.
AREA IMPIANTI SPA
Padova, ITALY
ALEYA BEIJING CO LTD
Beijing, CHINA
AREA IMPIANTI CORP
New York, USA
AREA IMPIANTI LTDA
São Paolo, BRAZIL
WHO WE ARE
Thanks to the know how achieved in 50
YEARS of previous experiences, the
company focuses its core business in the
realization of turnkey flue gas treatment
plants and over time has developed a
vocation for the production of energy
from renewable sources.
AREA IMPIANTI was established in 1990 in Italy by the founding
members Marcolin, Cardin and Zatti, who currently manage the
group.
The Company is today locally organized
in 4 continents.
The headquarters is located in PADOVA, on the North-Est of Italy, 40 km
faraway from Venice.
The Group AREA IMPIANTI counts 55 collaborators, most of them are
engineers and technicians with extensive experience in the sector.
THE COMPANY
Among the leading managers, the Group numbers its main members,
permitting also the company to have a short and agile decision chain,
suited to the particular requests of the customers.
THE STRUCTURE
The structure of AREA IMPIANTI for
its nature is strictly focused on its
OWN TECHNOLOGY.
While its men and women are able
to manage directly every aspect of
the construction of large turnkey
plants, the most tightly productive
aspect is outsourced and controlled
according to the Quality System
Certification.
This allows the company to remain
flexible and independent from a
context that would forbid her to
realize with successful installations
worldwide.
Area Impianti as been listed on the
Italian alternative stock market
(MAC), between 2007 and 2012.
Angelo Marcolin (CEO)
Ivana Cardin (CFO)
Francesco Zatti
(Tech. Dir)
Alba Private Equity
Own shares
Other Investors
ISO 9001: 2008
for quality management system
ISO 14001: 2004
for environmental management
system
BS OHSAS 18001: 2007
for occupational health and safety
management system
Certification SOA OS14 in Class
VIII
This is a particular certification
that is needed in Italy to
participate to public tenders and
works. AREAIMPIANTI is
authorized to offer, carry out
design and erection of plants with
unlimited size and value of the
plant.
The international presence is indeed strong and growing.
Consolidated market
Next target market
Heat recovery and power generation plant
Flue gas treatment plant
WORLDWIDE MARKET
Nr of plants: 1-5 5-10 >10
FLUE GAS TREATMENT
BUSINESS LINES
HEAT RECOVERY and POWER GENERATION
AREA IMPIANTI produces flue gas treatment plants for the
reduction of pollutant emissions produced by melting or
combustion processes. With its know-how, the company realizes
all the components for the treatment of:
- Dusts - Acid gases - Nox
- CO - Dioxins …and other more
AREA IMPIANTI undertakes the role of EPC Contractor by
proposing itself to the market as producer and manager of
complete power and thermal energy lines. The energy source,
always “renewable”, can result from combustion or heat
recovery processes. Able to realize these plants with the Project
Financing formula.
HEAT RECOVERY BIOMASS to ENERGY WASTE to ENERGY
A clever renewable energy source ORC SYSTEM
technology of the future in our present Problem into opportunities
METAL INDUSTRY CEMENT INDUSTRY GLASS INDUSTRY
Glass has never been so clean Solutions that will break the standards Concrete solutions
SECTORS
The priorities of a glass maker:
• continuity of production
• furnace pressure management
• no additional maintenance
The heat recovery idea
The idea:
• proven, flexible, low maintenance/operation technology
• no risks of corrosion/clogging
• high efficiency in a wide range without help of fossil fuel
The target: to use the “lost third” of the furnace energy balance
Heat Exchange in Glass Industry
Before ORC systems
Start-up0 Country Furnaces Flue gas treatment description Wet flow rate and temperature
q.ty glass total pull Cooling system Treatment system Reagent injected System inlet At filter
2012 France 1 furnace water glass 216 t/d Heat exchanger Bag filter lime 17.500 Nm3/h 500°C 19.300 Nm3/h 205°C
2011 France 1 furnace glass fiber
(borosilicate) 130 t/d
Dilution + Heat exchanger
Bag filter lime 13.000 Nm3/h 400°C 14.000 Nm3/h 190°C
2011 Bulgaria 1 furnace float glass 750 t/d Heat exchanger Heat recovery
ESP + SCR DeNox lime + Ammonia 109.000 Nm3/h 550°C 111.000 Nm3/h 400°C
2010 U.K. 1 furnace container glass 270 t/d Air/gas exchanger Bag filter lime 26.000 Nm3/h 31.000 Nm3/h
2010 Italy 1 furnace container glass 300 t/d Air/gas exchanger Bag filter lime
2009 NL 2 furnaces container glass 640 t/d Dilution + Air/gas
exchanger Bag filter lime 24.000 Nm3/h 25.000 Nm3/h
2009 France 4 furnaces container
glass/flaconnage 82 t/d Air/gas exchanger Bag filter lime 24.500 Nm3/h 27.000 Nm3/h
2008 Italy 1 furnace container glass 75 t/d Air/gas exchanger Bag filter lime 8.500 Nm3/h 485°C 9.500 Nm3/h 182°C
2007 Spain 2 furnaces container glass 200 t/d Air/gas exchanger Bag filter lime 37.000 Nm3/h 500°C 37.000 Nm3/h 200°C
1999 Italy 30 furnaces artistic glass Dilution + exchanger Bag filter - 20.000 Nm3/h 300°C 35.000 Nm3/h 180°C
1998 Italy 11 furnaces artistic glass Dilution + exchanger Bag filter - 16.000 Nm3/h 300°C 20.000 Nm3/h 180°C
1995 Italy 2 furnaces glass pipe
(borosilicate) Dilution + exchanger Bag filter lime + Nepheline 6.000 Nm3/h 930°C 52.000 Nm3/h 130°C
1994 Italy 1 furnace glass fiber
(borosilicate) Dilution + exchanger Bag filter Bicar 5.000 Nm3/h 900°C 9.000 Nm3/h 180°C
1992 Italy 4 furnaces artistic glass (opal) Air/gas heat exchanger
Bag filter lime 18.000 Nm3/h 400°C 27.000 Nm3/h 180°C
Heat Recovery in Glass Industry
ORC references
Systems started-up 2015-2016 Container 1 Float 1 Float 2
Furnaces tpd 4x400 2x750 2x750
Flow rate wet per furnace Nm3/h 32.400 100.000 100.000
Inlet T °C 450 500 500
Outlet T °C 180 180 180
Flue Gas Treatment Y/N N N Y
Max Heat Recovered kW 13.897 22.840 20.018
Max Gross Electric Power kWe 3.256 5.541 4.667
Max Net Electric Power kWe 2.685 4.568 3.632
Max Hot Water Production kW 3.759 - 5.600
• 24 years in glass industry
• Experience in float, container and tableware glass
• Flue gas knowledge
• Several H.E. already installed in glass industry
• Integration with air pollution control
• Experience worldwide using local subcontractors
• References in operation in glass industry
with ORC units for 13,5 MWe
Company strength
Basic data for
Sample plant
Item unit Each of 4 furnaces
Flow rate Nm3/h wet 32.400
Temperature at delivery °C 450
Temperature at WHRS outlet °C 180
Available heat per furnace kW 3474
Heat requirement,
summertime kg/h (70-90°C) 60.000 (1400 kW)
Heat requirement, wintertime kg/h (70-90°C) 160.000 (3750 kW)
Present situation and project
requirements in Sample plant
• Four furnaces of medium size
• Distance not negligible between furnaces
• Need for heat generation in winter and summer season
• Corrosion risk at low temperature
• Untreated flue gases, need for automatic cleaning system
• System prepared for future insertion of flue gas cleaning system
Proposed solution for
Sample plant
ORC
Water heater
FA HE
FB HE
FC HE
FD HE
The Organic Rankine Cycle
Basics Flue gas
inlet Flue gas
outlet
Thermal
Oil
• No need of auxiliary equipments for
steam cycle
• No need of licensed boiler operator
• Reduced downtime due to maintenance
(higher availability)
• No interference between glass and power
production
• New very efficient generation of organic
fluid turbines
• Higher flexibility of turbine
Advantages of Organic Rankine Cycle
Oil to be heated at T = 250 – 320°C -> the higher the better
The Organic Rankine Cycle
Scheme
The Organic Rankine Cycle
Fluids, sizes, efficiencies
Working fluids
Type of fluid Examples Applications
Refrigerants
(HFC)
R134a,
R234fa,..
Geotermal power plants,
Low temperature WHR
Siloxanes MM, MDM,… WHR
CHP
Hydrocarbons Cyclopentane
, Toluene
WHR
0
50
100
150
200
250
300
350
400
-1500 3500 8500
T [°
C]
s [J/kg-K]
Water Cyclopen R245FA
MDM MM
Performances
Thermal
vector
Thermal vector
temperature [°C]
Size
[kWe]
Efficiency
[%]
Thermal oil 270÷320 1000 ÷ 6000 22÷25
Pressurized
water
200÷230 < 1000 15÷18
Superheated STEAM Rankine cycle Organic Rankine Cycle (O.R.C.)
PROS:
• Wide choice of suppliers
• Working fluid is cheap and easily available
• Flexible operation under variable CHP request
• No need for intermediate thermal carrier
PROS:
• “Dry” working fluid no superheating need
(longer life of the turbine)
• Available for small scale plant (<500 kWe)
• Suitable for medium/low enthalpy heat
• Package/skid solution (easy transport & erection)
• High efficiency at partial load operation
• Very low maintenance (high availability)
CONS:
• Need for water treatment (demineralization),
water control (analysis) and equipment
(deaerator)
• Need for licensed boiler operator
• PED requirements for boiler
• Need of additional burners
• Limited recovery due to corrosion risk
CONS:
• Some working fluids are explosive (ATEX)
• Need for intermediate thermal carrier (anyway it
limits the risk of acid corrosion in Gas HEs)
• Thermal oil has potential fire risk
• Standard solution with asynchronous generator
(synchronous generator is available upon request)
The Organic Rankine Cycle
Steam VS ORC
The Organic Rankine Cycle
Off-design performances
18.00
19.00
20.00
21.00
22.00
23.00
24.00
40.00 50.00 60.00 70.00 80.00 90.00 100.00 110.00
η [
%]
Thermal Load [%]
Off-design of a MW-size ORC plant
Gross Efficiency
Net Efficiency*
* Only pump
consumption
The performance curve refers to an ORC system performed by cyclopentane and driven by thermal oil at 300°C.
High cycle efficiency
even at strong partial
load
Very wide range of operation
-> not significantly influenced by furnace operation
The Organic Rankine Cycle
Turbines
The Organic Rankine Cycle
Pictures
Proposed scheme
Sample plant
Fx
ESP SCR
3721 kW
180°C 325°C
Hi-T HE
325°C 450°C
1635x4 kW
320°C
Low-T HE
ORC
150°C
1839x4kW
Water heater
2450 kW
Winter season
Proposed scheme
Sample plant
Fx
ESP SCR
1395 kW
180°C 325°C
Hi-T HE
325°C 450°C
1635x4 kW
320°C
Low-T HE
ORC
150°C
1839x4kW
Water heater
3030 kW
Summer season
Proposed scheme alternative
Sample plant
Fx
FGT
3721 kW
Hi-T HE
180°C 450°C
320°C
ORC 150°C
3474 x4kW
Water heater
2450 kW
Winter season
Fx
FGT
1395 kW
Hi-T HE
180°C 450°C
320°C
ORC 150°C
3474 x4kW
Water heater
3030 kW
Summer season
Proposed scheme alternative
Sample plant
Performance values
Referring to ISO ambient conditions (15°C, R.H. 65%)
Tolerance on thermal input/output is ±5%
Item unit Total of 4 furnaces,
wintertime
Total of 4 furnaces,
summertime
Total available heat per furnace kWth 13896 13896
Hot water generated kWth 3721 1395
Power to ORC kWth 10139 12488
Gross Power generated kWe 2450 3030
Gross electric efficiency % 24,2 24,3
Total internal consumption incl. ID
fan kWe 545 555
Net power generated kWe 1905 2475
Net electric efficiency % 18,8 19,8
P&ID
ID fan
Furnace
Hi-T Heat
exchanger
Organic
Rankine Cycle
Cooling towers (3x2
fans each)
Hot Water
generator
Low-T Heat
exchanger
P&ID alternative if lower water T is
needed
Plant heating
Water/water HE
Cooling towers (3x2
fans each)
Organic fluid
condenser
Proposed equipments
Detail: Heat exchanger
Proposed equipments
Detail: Heat exchanger
Proposed equipments
Detail: Heat exchanger
Detail:
Vertical chain cleaning system
Float glass
WHR
After 8000h
without stop
for cleaning
the gas
passages are
not clogged
Detail:
Horizontal compressed air cleaning
system Each pipe blows
compressed air
horizontally
between tubes of
heat exchanger
The pulse jet avoids
dust build-up
horizontally
The pulse jet is
operated by timer
Detail: Combined effect of
cleaning of Heat exchanger
Vertical cleaning
Horizontal cleaning
Proposed equipments
Detail: Cooling towers
Example of Lay-out
ID fan
Furnaces
Heat exchangers
Organic
Rankine Cycle
Cooling towers (3x2
fans each)
Example of Lay-out
Example of Lay-out
Example of Lay-out
Our proposal’s strong points
• High efficiency
• High reliability of the equipments
(low vibration turbine, back-up redundant equipments, robustness
of equipments, proven cleaning system)
• Always giving priority to furnace operation
• Everything prepared for future flue gas cleaning (incl. ID fan)
• deep knowledge of the flue gas characteristics
Keys for an
optimized solution
• define the available sources
• define the operating range
• flue gas treatment requirement: present and future
• define the thermal needs during the year
• optimize lay-out with common equipments
AREA IMPIANTI S.p.A. via Leonino da Zara, 3/A – 35020 Albignasego (PADOVA - ITALY)
Tel +39.049.8626426
[email protected] www.areaimpianti.it
AREA IMPIANTI CORP Queens Plaza N
New York City (NY - USA)
Tel. +1 718 937 7770 [email protected]
[email protected] www.areaimpianti.it
AREA IMPIANTI LTDA Av. Cidade Jardins 400, 7 Andar
São Paulo (BRAZIL)
Tel. +55 11 9.7285-1842 [email protected] [email protected]
www.areaimpianti.it
AREA IMPIANTI BEIJING Level 6, Beijing Sun Palace Building,
n° 12 Taiyanggong Middle Road
Tel. +86 10 64697089 [email protected]
www.areaimpianti.cn
