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
member

Copyright©–TurbodenS.r.l.Allrightsreserved
About Us
Turboden is a leading European company in development and production of ORC
(Organic Rankine Cycle) turbogenerators. This state of the art equipment generates
heat and power from renewable sources and heat recovery in industrial processes.
The company was founded in 1980 in Milan by Mario Gaia, Associate Professor at
Politecnico di Milano, teaching Thermodynamics, Renewable Energy and specifically
studying ORC systems. At present Prof. Gaia is Honorary Chairman. A number of his
former students are key persons in the Company and the whole Company is
permeated by innovative and research oriented spirit.
Turboden has always had a single mission: to design ORC turbogenerators for the
production of heat and electrical power from renewable sources, while constantly
striving to implement ORC technical solutions.
2

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!
3
Experience

260 biomass projects in 30 countries (5 CCHP)
9 Waste to Energy projects in 6 countries
4

• 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 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
Waste to energy
“fuel”
5
What We Do

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
6
Water vs High Molecular Mass - Working Fluid

Steam Rankine Cycle
Temperature Entropy
Temperature
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
7
ORC provides significant advantages as compared to steam

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
8
A
B
C
D
Energy can
neither be
created nor
destroyed, but it
can be wasted
’’
‘‘

Heat source
Turbo
expander
Heat
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
9

Waste to Energy applications
Steam or hot water from incinerator/boiler
1. Bunker
2. Furnace
3. Heat recovery Steam
generator
3a. Economizer
3b. District Heating
Network
3c. ORC
4a. ESP
4b. Chemical Reactor
4c. Bag Filter
4d. Denox
5. Chimney
3b
1. in existing plant as second user to existing district heating network
2. for new installation also in power only configuration
A
3
4a
3a
2
1
4b 4c
4d
5
3c
10

Plant type: 62,000 t/yr MSW
plant, in operation since 1976
2 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
11
Mirom, Belgium

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
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
12
Nantes, France

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 Rhin
Rhone) – 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
13
Lons le Saunier, France

 Internal
combustion engine
 Syngas combustion
boiler
 Syngas Turbine
Heat exchanger
 Direct Exchange
 Thermal oil
Mechanical
/electric
power
 Cooling tower
25 ÷ 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
14

Plant type:
Industrial waste synthesis gas burned in a thermal
oil boiler
Customer: ITC-KA Enerji Uretim Sanayi VE Ticaret
A.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
15
Ankara, Turkey

Internal
combustion engine
Heat exchanger
 Direct Exchange
 Thermal oil
Mechanical/
electric power
 Cooling tower
7 ÷ 10% additional power(1)
Note: 1) Percent of the prime mover nominal power
Landfill
gasification
Landfill engines exhaust gasC
16

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
17
Helsinki, Finland

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
18

Photo:courtesyofAlbanyCountySewageDistrict
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
19
Menands, US

20
CCHP – Combined Cooling Heating Power
cold
water
ABSORPTION
CHILLER
hot
water
ELECTRIC
POWER
DISTRICT
HEATING
cold
water
COOLING
SYSTEM
BIOMASS
POWERED
BOILER
BIOMASS
ORC
Thermal
oil
USE IN
PUBLIC
BUILDINGS,
HOTELS, …

21
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

22
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

23
Conclusions

Happy to answer your questions…
member membermember

Back-up Slides
25

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 cycle
efficiency at 50% of load
Turboden ORC units automatically
adapt the cycle at the ambient
temperature variations
ORCActualEfficiency/ORCNominalEfficiency
26
Flexible and automatic

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
27

28
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 HR
Status: prospect
Electric power generated: 2 MW to off-set the sawmill own
consumption
Key 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

29
Project features
Existing 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%
Electricity
price (c$/kWh)
Cash flow
(M$)
PBT (yr) IRR 15yr
NVP 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)

30

31
• EXPERIENCE
• GUARANTEES
• HIGH AVAILABILITY
• REMOTELY CONTROLLED
• FULLY AUTOMATIC
• UNATTENDED
• LOADS FLEXIBILITY
• NO WATER
• MODULAR EXPANSION
PEACE OF MIND
So, what do we really offer?

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

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