Turboden ORC energy recovery:

best practices in energy intensive industries

Alessandro Foresti Turboden Director

Energy recovery in industry Best practice to implemention

Duisburg, Wednesday 12th June 2013

Agenda

ORC technology
Features and advantages

About Turboden
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30 years of experience

Application
Turboden ORC references
H-REII and H-REII Demo: Demonstration WHR plant in steel industry

References in Energy Intensive Industries

Interface with process
References
First glance at economics

Conclusion

Turboden ORC

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Biomass

Geothermal

electricity
heat

Solar

Waste-heat

standard units from 200 kW to 10 MW

customized solutions up to 15 MW

The Thermodynamic Principle: The ORC Cycle

Turbine
Electric Energy

Temperature

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Generator
Heat carrier
Rigenerator

Evaporator

Water
Condenser
Entropy

Pump

The turbogenerator uses the hot temperature thermal oil to pre-heat and vaporize a suitable organic
working fluid in the evaporator (834). The organic fluid vapor powers the turbine (45), which is
directly coupled to the electric generator through an elastic coupling. The exhaust vapor flows through
the regenerator (59) where it heats the organic liquid (28). The vapor is then condensed in the
condenser (cooled by the water flow) (961). The organic fluid liquid is finally pumped (12) to the
regenerator and then to the evaporator, thus completing the sequence of operations in the closed-loop
circuit

ORC vs. traditional steam cycle

Water / Steam
Temperature

SATURATION CURVE WITH PARALLEL SLOPES

No need to superheat
Entropy

ORC

Moderate temperature/pressure

SMALL ENTHALPY DROP

Large slow turbine

Temperature

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Dry vapour expansion

Rigeneration

High efficiency
Entropy

Advantages of Turboden ORC Heat

Recovery Plants
No erosion of blades, low mechanical stress of the turbine
No corrosion issues (use of non aggressive working fluid)

Demonstrate very good partial

load behaviour (see curve)
Do not consume water
No need of water treatment
Selection of more appropriate
working fluid
Low O&M requirements
ORC plants remotely monitored

ORC Part Load efficiency

ORC Actual Efficiency / ORC Nominal Efficiency

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Ease of integration in main process (by-pass); do not affect plant operations

100%
90%
80%
70%
60%
50%
40%
30%
20%
0%

20%

40%

60%

80%

100%

Actual Load / Nominal Load

Over 30 years of experience

Prof. Mario Gaia makes
experience in the field of ORC
within his research group at
Politecnico di Milano

Copyright Turboden S.r.l. All rights reserved

1976 First prototype of a

solar thermodynamic ORC

Turboden installs ORC biomass plants,

especially in Austria, Germany and Italy
Turboden plans to enter new markets,
with focus on North America
First heat recovery applications
First direct exchange ORC 600 KWe
connected to Diesel Engine

60-70

1980-1999

2000-2009

1980 Prof. Mario Gaia founds

Turboden to design and manufacture
ORC turbogenerators
Turboden develops research projects
in solar, geothermal and heat recovery
applications
1998 First ORC biomass plant in
Switzerland (300 kW)

2009-2013

MHI acquires the

majority of Turboden.
Italian quotaholders stay
in charge of management
Today - Over 250 ORC
plants in the world, 200 in
operation
2013

2009 Turboden achieves 100 plants

sold
United Technologies Corp. (UTC) acquires
the majority of Turbodens quota. PW Power
Systems supports Turboden in new markets
beyond Europe
UTC exits the power market forming
strategic alliance with Mitsubishi Heavy
Industries
PW Power Systems becomes an MHI
group company
7

Turboden ORC units in the world 253 - 28 Countries

Installed power 333 MW
Wood Biomass 221 units (300 kW 6.5 MW)
Combined cycles 13 units (500 kW 4.5 MW)

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In Europe
Germany

80

Italy

71

Austria

30

Spain

etc

Industrial heat recovery 9 units (700 kW 7 MW)

Municipal waste treatment 4 units (500 kW 6 MW)
Geothermal 6 units (1 MW 6 MW)

Oil&Gas Player
Russia

Oil&Gas Player
Canada

Copyright Turboden S.r.l. All rights reserved

ORC Heat Recovery in Energy Intensive Industries

A good energy efficiency

practice: decrease final
energy consumption
(electricity, heat, etc.)
recovering EII waste heat
streams

Energy
Intensive
Industries
wasted heat
gas, liquid,
vapour

Heat
Exchanger

process or
thermal
users: both
civil and
industrial

ORC
generator

Thermal
energy
Thermal
Energy

Electricity
9

Copyright Turboden S.r.l. All rights reserved

ORC interfaces with the process

ORC battery limit

10

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Interfaces with process: heat carriers

Heat carriers:
Thermal oil
Saturated steam
Water (e.g. geothermal, moderate temperature heat recovery)
Molten Salts (e.g. CSP)

Heat carrier loop features:
Multiple heat sources
Layout flexibility
Ease of operation (process upset tolerance)
Energy buffer

Direct heat exchange with hot gas stream is feasible,
under certain conditions
Layout, heat exchanger size, 1 source to 1 ORC, etc.

Heat Recovery In Energy Intensive

Industries: Turboden approach
Several schemes can be studied to maximize electric power output
minimizing the investment cost
Collaboration with process owner and heat exchanger suppliers to best
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match the specific plant features

Flexible ORC solutions:

different working fluids (temperature ranges, ORC size, etc.)

different heat carriers (temperature ranges, specific issues, etc.)

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Turboden Heat Recovery references

Holcim Romania Holcim Group
Client: Holcim Romania - Alesd
Clinker production capacity: 4.000 ton/day
Heat source: exhaust gas @ 360C (PH) and hot air @ 250 C (CC)
Copyright Turboden S.r.l. All rights reserved

Thermal oil (PH) and pressurized water (CC) heat recovery loops
Cooling: water condenser + wet cooling tower
ORC electric power: ~ 4 MWe
Started up: July 2012 (4,200 working hours)
Availability: >98%

Holcim Slovakia Holcim Group

Site: Rohoznik (Slovakia)
Client: Holcim Slovensko A.S.
Status: to be started up end 2013 / beginning 2014
Heat Source: exhaust gas from PH and CC
Heat carrier: thermal oil
Cooling: water condenser + wet cooling tower
Electric power: 5 MWel

Slovakia

Turboden Heat Recovery references

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Cimar - Italcementi Group

Site: CIMAR ITALCEMENTI GROUP (Morocco)
Clinker production capacity: 5.000 ton/day
Heat source: PH exhaust gas at 330C
Cooling: water condenser + air-coolers No water consumption
ORC electric power: 2 MWe
In operation since IV quarter 2010
Working hours: 16.000 h
Availability: >98%
The plant is being hybridized with CSP (Concentrated Solar Power) taking
advantage of the ORC extra capacity

AGC Glass Europe

Site: Cuneo - Italy
Client: GEA Process Eng
Final Client: AGC Glass Europe
Started up: March 2012
Heat source: gas @ 500C from glass production process
Heat carrier: thermal oil
Cooling: water condenser + air-coolers
Electric power: 1.3 MWel

Turboden Heat Recovery references

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Refractories RHI Group Austria

Client: RHI GROUP (Radenthein - Austria)
Refractory production capacity: 250 ton/day
Heat source: refractory ovens exhaust gas @ 500 C
Gas cooled down to ca. 150 C
ORC electric power: ca. 1 MWe
Started up: Q1 2009

Pipeline compressor station

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
In operation since IV quarter 2011

Heat Recovery Reference in Steel Industry Direct exchange

Billet reheating furnace at steel rolling mill
Client: NatSteel Tata Group
Site: Singapore

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Started up: February 2013

Heat source: exhaust gas from LFO combustion, @ 400C

Direct exchange between exhaust gas and working fluid
ORC electric power: ~ 0.7 MW
4th Direct exchange ORC unit in operation

16

European Focus on Energy Efficiency:

H-REII and H-REII DEMO projects.

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H-REII (2010-2012)
Quantify the heat recovery potential in
the Italian EIIs (pioneer EU project)
Promote energy efficiency policy in
Italy (disseminating best practice)
Extending

from Italy to Europe

H-REII DEMO (2012-2014)

Quantify the heat recovery potential in
the European EIIs
Promote energy efficiency policy in
Europe (disseminating best practice)
Support demonstration of ORC heat
recovery plant in the Steel Industry

H-REII Demo Demonstration Plant

Electric Arc
Furnace
(EAF)
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ESF - Riesa (Germany)

Reduce
consumption

Exhausted
gases

Heat
exchanger
Electric
energy

67%

ORC
3 MWe

Expected start up:

Q1 2014

Tenova RE Energy
GMBH
33%

Thermal energy
~ 30 t/h steam at
27 bar - 245C

Industrial thermal
user

18

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First glance at economics: CAPEX / OPEX

Process heat exchanger, heat carrier

loop and balance of plant

ORC unit
ORC module is only a portion of the waste heat
recovery system
Specific investment cost depends on several
factors, most importantly the ORC size, but also
specific applications, Clients requirements and
needs, cooling system, etc.
ORC only OPEX in the range of 2-5 % of ORC
Capex / year

Specific investment cost highly affected by

project-related and site-related factors, such as:

Main process characteristics

Potential multiple heat sources
Layout constraints
Climate conditions at the installation site
Grid connection (voltage, distance)
Civil works
Erection cost

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Barriers and Prospects

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ORC waste heat recovery in European EII is a best practice:

of energy efficiency for a sustainable industry

increasing industries competitiveness

promoting a new European supply chain to export

helping in saving/creating new jobs

but investment payback time is limited by:

investment cost
electricity price with preferential rates for EII in some countries
Incentives for energy efficiency in industry only in few Member States
lower operating hours due to economic downturn
Recomended policy actions:

funding and guarantees to reduce barriers in project financing

preferential prices for EII must promote investments for energy efficiency

dissemination: increase industrial players awareness of BAT (ORC, etc.)

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Thanks for your attention!

For further information contact:

alessandro.foresti@turboden.it
marco.baresi@turboden.it
+39 030 3552001
www.turboden.com