12 COM.P 21 Rev.10

Turboden ORC plants for Industrial Heat Recovery
The proven way to address environmental sustainability
Doc.: 12-COM.P-21-rev.10
Update: 21/10/2013
ORC Applications Heat Recovery
Copyright Turboden S.r.l. All rights reserved
Biomass Heat Recovery Geothermal Solar Thermal

Power
Heat Recovery
Turboden ORC 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 200 kW and 15 MW electric.
2
HR Applications / Energy Sources
Gaseous 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 metal furnaces
exhaust gas
Exhaust Gas from waste incineration (civil/industrial)
Liquid sources: Refineries hot streams

Cooling water (or other fluids) loops in industrial
processes
Jacket cooling water of reciprocating engines
Condensing sources: 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)
3
Heat Recovery from Reciprocating Engines: up to 10% addl Power
NOTE: Indicative values assuming ambient ISO conditions, Engines operating at nominal load;
calculations based on Engines exhaust gas properties as reported in specific suppliers web sites.
4
Heat Recovery from Internal Combustion Engines: Heat Sources
Turboden's ORC modules for heat recovery have a power output between 200 kWe up to 15 MWe: the minimum thermal power
necessary to employ a Turboden ORC is approximately 1.2 MWt.
Exhaust gas: Typically contains between 1/4 and 1/3 of the fuel heat, being released at relatively high
temperatures (300 500C).
ORC production reaches up to 10% of engine power output
Heat Recovery from Internal Combustion Engines: Reference Projects
Project ORC Module Site Engines
Pisticci I TURBODEN 18 HR SPLIT (1.8 MWe) Pisticci (IT) 3 x 8 MWe Wartsila Diesel engines
In operation since IV quarter 2010
Oxon TURBODEN 6 HR SPLIT (0.6 MWe) Pavia (IT) 1 x 8 MWe MAN Diesel engine
FinPower TURBODEN 6 HR DIR. EXCH. (0.6 MWe) Visano (IT) 1 x 7 MWe Wartsila Diesel engine
In operation since II quarter 2009
Pisticci II TURBODEN 40 HR SPLIT (3.8 MWe) Pisticci (IT) 2 x 17 MWe Wartsila Diesel engines
Cereal Docks TURBODEN 6 HR DIR. EXCH. (0.6 MWe) Portogruaro (IT) 1 x 7 MWe Wartsila Diesel engine
In operation since I quarter 2012
2 x 1 MWe JGS/GE gas engines +
Eukrasia TURBODEN 6 HR SPLIT (0.6 MWe) Catania (IT)
3 x 0.8 MWe JGS/GE gas engines +
1 x 0.6 MWe JGS/GE gas engine
TURBODEN 10 HR cogenerative (1 MWe) 2 x 2 JGS/GE gas engines
Ulm Senden (DE)
In operation since III quarter 2012 (+ additional heat from the process)
TURBODEN 6 HR cogenerative (0.6 MWe)
Kempen Kempen (DE) Gas engines
TURBODEN 10 HR (1 MWe)
Mondopower Chivasso (IT) 1 x 17 MWe Wartsila Diesel engine
TURBODEN 14 HR (1.3 MWe) mmssuo (FIN) 4 x 4 MWe MWM gas engines
HSY
In operation since III quarter 2011
TURBODEN 10 HR SPLIT (0.987 MWe)
GazProm2 Moscow region (RU) 5 x 2 MWe MTU engines
Under construction
TURBODEN 7 HR DIR. EXCH. (0.7 MWe)
Fater Pescara (IT) 1 x 8 MWe Wartsila Diesel engine
6
HR from Gas Turbine : 25-35% addl Power (Gas Compressor Stations)
NOTE: Indicative values assuming ambient ISO conditions. Gas Turbines operating at nominal load;
calculations based on Gas Turbine exhaust gas properties as reported in specific suppliers web sites.
7
Heat Recovery from Gas Turbine
Reference Plant
Heat recovery from Solar CENTAUR gas turbine in a Gas Compressor station in Canada
Gas Turbine prime power: 3.5MWe

Gas Turbine efficiency: 28%
ORC electric power: 1MWe

General Contractor: IST (Innovative Steam Technologies)

Final Client: TransGas
Reference Plant
Heat recovery from Solar TITAN 130 gas turbine in a Gas Turbine Power Plant (GTPP) in
Russia (Moscow region)
Gas Turbine prime power: 25MWe

Gas Turbine efficiency: 30%
ORC electric power: 3MWe-Direct exchange cogenerative solution

ORC thermal power: 15 MWt of hot water at 90C
Customer/Project Developer: PolyImpex/Energo development LCC

Under construction (start-up foreseen IV quarter 2014)
8
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.
9
Reference Case study: PRS gas waste heat recovery
Clinker production capacity: 5,000 ton/day

Heat source: exhaust gas @ 330C
Gas cooled down to 220C (extra heat used for raw material pre heating)
ORC electric power: ca. 2 MWe
Client: CIMAR ITALCEMENTI GROUP (Morocco)

10
Cement: Alesd Holcim Romania Project
Project: Holcim Romania

Heat Source: cement production process
Clinker production capacity: 4,000 ton/day

Heat source: exhaust gas @ 360C (PRS) and hot air @ 250 C (CC)
Thermal oil (PRS) and pressurised water (CC) heat recovery loops
ORC electric power: ~ 4 MWe
Client: Holcim Romania Holcim Group (Romania)

Romania
11
Project Holcim Slovakia

Reference Case study: PRS and CC gas waste heat recovery
Slovakia Clinker production capacity: 3,600 ton/day

Heat source: exhaust gas @ 360C (PRS) and hot air @ 310C (CC)
Thermal oil heat recovery loops
Client: Holcim Slovakia Holcim Group (Slovakia)

Under construction; start up expected in IV quarter 2013
12
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 @ 500C
Gas cooled down to ca. 150C
Client: RHI GROUP (Radenthein - Austria)

13
Heat Recovery in Steel Industry
Main exhaust gas streams available:
Relatively clean exhaust gas at

Rolling, forging moderate temperature
Cost effective for ORC 600/800 kWe
Strip processing
Heat treatment Exhaust gas: high flows, high
temperatures, high dust content, large
BOF variations in operating cycle,
environmental constraints
Blast furnaces Interface between process and energy
Sinter recovery unit is critical
ORCs proposed where heat recovery

Electric Arc exchangers are available
Furnace
14
Steel (rolling mill): Singapore Natsteel project
Project Natsteel Singapore

Reference Case study: rolling mill reheating furnace waste
heat recovery
Heat source: exhaust gas from LFO burning, @ 400C

Direct exchange between exhaust gas and working fluid

ORC electric power: ~ 0.7 MWe
Client: Natsteel Tata Group

15
Heat Recovery from Electric Arc Furnace
25% 30% of the power

inserted in the furnace is
lost in the exhaust 150 - 350 C
200 - 900 C
300 - 1600 C
70% of the lost

power could be recovered
Target:
3-5% of the
EAF installed
power
ORC
16
Heat Recovery from Electric Arc Furnace
PROJECT IN A GERMAN IRON&STEEL FACTORY

Exhaust gas from EAF (100 t) with steam production
Primary heat source: exhaust gas from EAF

Steam production:
The steam is produced from two different heat sources:
1. Pipe to pipe duct, modified to work with pressurized water at the boiling point
2. Substitution of the quenching tower with a shell and tubes heat exchanger which
produces steam.
Steam produced: ~ 30 t/h of steam at 27 bar - 245C
Steam available for the ORC unit:

~ 20 t/h of steam at 27 bar and 245C (10 t/h is delivered to an industrial process)
Gross power output ORC unit: ~ 3 MWe
High flexibility of the heat recovery system: the ORC properly operates with a steam flow
rate between 2 and 22 t/h, automatically adapting its operation to the different operating
conditions
THE SYSTEM AUTOMATICALLY FOLLOWS THE EAF MELTING CYCLE
17
Heat Recovery in Glass Industry
Heat source main properties:
High exhaust gas temperature

Constant operating conditions
Exhaust gas with moderate dust content
Exhaust gas must be cooled not below 200C
High temperature ORC cycle employed:

ORC electrical efficiency up to 25%
18
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 500C
ORC electric power: ca. 1.3 MWe

Final Client: AGC Glass Europe Cuneo Plant

General contractor: GEA Bischoff
19
Heat Recovery Reference Case study
Plant type:
Heat recovery from pressurized
water boiler in waste incinerator
Customer :
MIROM (Roeselare-Belgium)
In operation since:
II quarter 2008
Heat source:
hot water at 180C (back 140C)

Cooling source:
water/air
Total electric power:
3 MW el
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)
20
Heat Recovery Data Collection Sheet
Title: Heat recovery data collection sheet T-11Other notes:

.
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 Economical data

(*)E-1Operating time: .. hours/day
(*)T-2Temperature: .. C
.. hours/year
E-3Energy sources:
(*)T-3Flow rate: .. kg/s . Nm3/hr E-3aElectricity:
T-4Heat source characteristics Average cost: .. /MWh
T-4aComposition: E-3bMethane / natural gas:
CO2 % Yearly consumption: Nm3
CO % E-3cOther fuels: .
H2O % Yearly consumption: []
N2 % Average cost: .. [ / ...]
E-4Possible co-generative use:
Other () %
temperatures: / C
Other () % Additional notes: ..
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)
21
Turboden at a Glance
22
Turboden strong points
Operations & Aftermarket

R&D Sales/marketing Design manufacturing service
Participation in national Pre-feasibility Complete in-house Outsourced Start-up and

& EU research programs studies: evaluation of mechanical design components from commissioning
technical & highly qualified
Cooperation with EU Proprietary design Maintenance,
economical feasibility suppliers
Universities and and own technical assistance

of ORC power plants
Research Centres manufacturing of Quality assurance & to operation and
Customized ORC optimized project management
Thermodynamic cycle spare parts service
proposals to turbine
optimization In house skid
maximize economic Tools Remote monitoring
Working fluid selection & mounting to minimize & optimization of
testing & environmental - Thermo-fluid- site activities plant operation
targets dynamic programs
Thermo-fluid-dynamic
design and validation - FEA
Implementation & testing - 3D CAD-CAM
of control/ supervision - Vibration analysis
software
Many patents obtained
23
Turboden Facts & Figures
(Last update: January 2013)

24

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Turboden ORC plants for Industrial Heat Recovery

The proven way to address environmental sustainability

Biomass Heat Recovery Geothermal Solar Thermal

Gaseous sources: Internal combustion engines exhaust gas (ORC as bottom

Liquid sources: Refineries hot streams

Condensing sources: Refineries organic vapours to be condensed

Project ORC Module Site Engines

Gas Turbine prime power: 3.5MWe

ORC electric power: 1MWe

General Contractor: IST (Innovative Steam Technologies)

Gas Turbine prime power: 25MWe

ORC electric power: 3MWe-Direct exchange cogenerative solution

Customer/Project Developer: PolyImpex/Energo development LCC

Exhaust gas streams from cement

Main Exhaust Gas

Reference Case study: PRS gas waste heat recovery

Clinker production capacity: 5,000 ton/day

Client: CIMAR ITALCEMENTI GROUP (Morocco)

Project: Holcim Romania

Clinker production capacity: 4,000 ton/day

ORC electric power: ~ 4 MWe

Client: Holcim Romania Holcim Group (Romania)

Project Holcim Slovakia

Slovakia Clinker production capacity: 3,600 ton/day

ORC electric power: ca. 5 MWe

Client: Holcim Slovakia Holcim Group (Slovakia)

Reference Case study: Refractory ovens exhaust gas heat recovery

Refractory production capacity: 250 ton/day

ORC electric power: ca. 1 MWe

Client: RHI GROUP (Radenthein - Austria)

Main exhaust gas streams available:

Relatively clean exhaust gas at

ORCs proposed where heat recovery

Project Natsteel Singapore

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

Direct exchange between exhaust gas and working fluid

Client: Natsteel Tata Group

25% 30% of the power

70% of the lost

PROJECT IN A GERMAN IRON&STEEL FACTORY

Primary heat source: exhaust gas from EAF

Steam produced: ~ 30 t/h of steam at 27 bar - 245C

Steam available for the ORC unit:

Gross power output ORC unit: ~ 3 MWe

Heat source main properties:

High exhaust gas temperature

High temperature ORC cycle employed:

Reference Case study: Float glass production process

Glass production capacity: 600 ton/day

ORC electric power: ca. 1.3 MWe

Final Client: AGC Glass Europe Cuneo Plant

In operation since I quarter 2012

hot water at 180C (back 140C)

Title: Heat recovery data collection sheet T-11Other notes:

Operations & Aftermarket

Participation in national Pre-feasibility Complete in-house Outsourced Start-up and

Universities and and own technical assistance

(Last update: January 2013)

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