18. ws effective use of thermal energy in industry_idesa

Ingeniería y DiseñoEuropeo S.A.

ADRIÁN ARBOLEYAInnovation Manager

Bilbao, 23rd June 2016

VI CDTI-NEDO JOINT WORKSHOP

Organic Rankine Cycle

#WasteHeat The Effective use of termal energy in industry

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Corporate introduction

R&D strategy

ORC Operating principle

ORC IDESA Developments

LIFE+ BIOBALE Project

SUMMARY

Main Figures:

Turnover (2014): 350 M€

Employees (2014): more than 2,500

IDESA is a subsidiary company of

GRUPO DANIEL ALONSO (GDA)

Europe 60%

South America 24%

Asia (India) 16%

GRUPO DANIEL ALONSO

WINDARRENOVABLESDACERO

DANIMA I.AMBIENTAL

TADARSALOGISTICS

IDESA

SPAINASTURIAS

OVIEDO

AVILÉS GIJÓN

Where we are

Head office

More than 450 employees

“In-house” Engineering capacity: 130,000 h/year

Manufacturing capacity

Workshop data

More than 5,000 equipment manufactured

95 % of our turnover for worldwide services

800,000 h/year

90,000 ton/year

70,000 m2

9 bays around 230 m length each

Some Figures

projects carried out in more than 40 countries

Canada

USA

Mexico

Venezuela

Peru

Chile

Argentina

Uruguay

Brazil

Kazakhstan

India

Australia

China

Japan

Russia

Tunisia

Algeria

Morocco

Mauritania

Nigeria

Cameroun

Saudi Arabia

Qatar

UAE

Kuwait

Jordan

Egypt

Netherlands

Ireland

Belgium

UK

France

Portugal

Spain

Germany

Switzerland

Turkey

Greece

Bulgaria

Romania

Poland

Norway

Denmark

…

Global services

PRESSURE VESSEL MANUFACTURING

OFFSHORE OIL&GAS

INDUSTRIAL PLANTS

FIELD ERECTIONS AND SHUTDOWNS

Our business lines

ASME VIII Div. 1

ASME VIII Div. 2

TEMA

PD5500

EN 13445

API 650

AD-MERKBLÄTT

CODAP

GOST

Design codes

3D modelling and design:

Autocad

Solidworks

Smartplant 3D

Advanced analysis:

ANSYS Inc.

Nozzlepro

Caesar II

Metrology:

PC-DEMIS

Management:

PRIMAVERA P6

Mechanical design:

Compress

PV Elite

Finglow

PASSAT

Thermal design:

TASCH-HTFS

(among others)

Software

IDESA Job 2/675 (2 Coke Drums)

L x D x Thk: 33 m x 8.9 m x 48+3 mm

Weight: 380 mT

Material: SA-387 Gr.11 Cl2 + SS 410S Clad

Final Destination: USA

IDESA Job 2/784 (Heater)

L x D x Thk: 36 m x 11,5 m x 20/19/18 (insert plates 50 & 31

mm)

Weight: 420 mT

Material: SA-516 Gr.70

Final Destination: GREECE

IDESA Job 2/784 (Reactor / Scrubber)

L x D x Thk: 70 m x 7 m x 50 / 39 / 33 / 19 mm

Weight: 400 mT

Material: ASME SA-516 Gr. 70 & SA-387 Gr. 11 Cl. Cladded

SS410S


IDESA Job 2/784 (Gasifier)

L x D x Thk: 27 m x 15,5 m x 30 mm

Weight: 400 mT

Material: SA-516 Gr.70


IDESA Job 2/799 (Reactor CCR Platforming Process Unit)

L x D x Thk: 72 m x 2.8 m x 39 / 27 mm

Weight: 260 mT

Material: SA-387 Gr.11 Cl.2

Final Destination: MEXICO

IDESA Job 2/738 (Second. Crude Column)

L x D xThk: 51.6 m x 6 x 23 / 23+3 mm

Weight: 350 mT

Material: SA-516 Gr.70 + C276 / 317L Clad


IDESA Job 2/721 (Vacuum Column)

L x D x Thk: 50.7 m x 15 m x 34+3.2 / 33 / 18mm

Weight: 800 mT

Material: SA-516 Gr.70 + 317L Clad


IDESA Job 1/866 (Monopiles)

L x D x Thk: 70 m x 6,5/4,7 m x 60 to 110 mm

Weight: 800 mT

Material: S355NL/ML

Final Destination: GERMANY

Some References

Detail engineering, procurement and

construction of Degassing and WHB

Modules

Client: MARAVEN (Venezuela)

Engineering, procurement and

construction of new modular plant for

bioplastic production

Client: ABENGOA (Europe)

Construction services for carbon

capture and storage (CCS) Plant

Client: ENDESA-HUNOSA (La Pereda, Europe)

Some References

Engineering services for 10 refining process

units shutdown preparation and planning

Client: CEPSA (La Rábida Refinery, Europe)

Engineering services for UE-1 Project. Oil

sand plant modularization

Client: Syncrude (Canada)

Engineering, procurement and construction of

modular crude sampling package

Client: BECHTEL (Kazakhstan)

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&docid=6BPaP5LGn84-JM&tbnid=IFZl_mAt527D6M:&ved=0CAUQjRw&url=http://www.ugt.es/actualidad/2010/agosto/a05082010.html&ei=paWaU7TcMOTY0QX7pYCQCQ&bvm=bv.68911936,d.d2k&psig=AFQjCNG6ew1K1H80B8AHswkaQuKENuC66g&ust=1402730254910140

Some References

Engineering consultancy services for reviewing,

completing and updating of the Structural Design Criteria

for In-vessel Components (SDC-IC)

Client: Fusion for Energy (ITER Organization, Europe)

Engineering for new industrial

manufacturing process for graphene-

based inks by exfoliation and reduction

of graphite

Client: CSIC (Spain)

Slotted skirt design optimization for coke

drums

(fatigue resistance improvement)

Client: CHEVRON (USA)


Runs in parallel to our business lines

• Improvement of our productive systems

• Machinery

• Processes

• Industry 4.0

• Pilot plants development

• Biochemical

• Production

• Renewable Energies

• New technology niches

• Offshore

R&D Strategy 15


Pilot PlantDemonstrator Plant

BIORC BIOBALE

IDESA R&D Projects on ORC technology 16


ORC OPERATING PRINCIPLE

BOILER

WATER

HEAT SOURCE-THERMAL

ENERGY TO RECOVER

COLD SOURCE – COOLING WATER

COOLING

PUMP

EXPANDER

ELECTRICAL

GENERATOR

17


P&ID Proposed for BIORC Project 18


Straight vaporization of the organic fluid

Straight vaporization of the organic fluid (removal of the middle loop of thermal oil)

Sistema actual: vaporización indirecta de

fluido ORC

Simplication of theinstallation and removal of parasites consumptions

19


Vaporizer design implemented in BIORC

Jet/Spray moves to the right thecritical point

20


Preliminary dimensioning of vaporizer (BIORC) 21


Vaporizer smoke-side design choice

Smoke-side(design 19)

Presión (atm) Ǭ (W/m2) h (W/m2 K)

22


Smoke-side -design 20 (pass-loop 50 mm)

Presión (atm) Ǭ (W/m2) h (W/m2 K)

Vaporizer smoke-side design optimization 23


hmedia

(W/m2 K)Qconvección

(kW)Tentrada

(ºC)Tsalida

(ºC)Tpared

(ºC)Humos 93,01 30,3 1000 664,1 250,0

ORC 98,82 31,1 100,0 111,4 273,0

Vaporizer design organic fluid side 24


Vaporizer smoke-side design optimization

Postprocess smoke-side

Fluid – aire ideal gas

25


Vaporizer design organic fluid side

Postprocess organic fluid side – R245FA

Temperature R245FA = 118,05 ºC Qcedido R245FA = 32362,8 W

26


Vaporizer manufacturing drawings (BIORC) 27

www.tuinsa.com

Proyecto LIFE 13 env/es/000923 http://biobale.com

http://www.ayto-navia.es/index.asp

http://biobale.com/

http://www.idesa.net/index.php


¿What is LIFE BIOBALE PROJECT?

Use of bale forest residues biomass, for itsdirect combustion in a boiler.

Waste-to-energy → COGENERATION ELECTRICITY HEAT

DEVELOPMENT OF A DEMONSTRATING COGENERATION PLANT

FROM COMPLETE BALE FORESTRY WASTE BIOMASS

PROJECT OVERVIEW

http://biobale.com/



LIFE+ CO-FUNDING

LIFE+ Environment Policy and Governance

• LIFE is the EU’s financial instrument supporting environmental, nature conservation andclimate action projects throughout the EU.

• Innovation and/or demonstration projects that contribute to improve the enviromentalsituation into european countries.

NUMBER OF PARTICIPANTS: 4

LOCATION: Navia

LENGTH: 3 years

STARTING DATE: July 2014. ENDING DATE: May 2017

BUDGET: 1.767.893,00€

EU GRANT: 49,37% of the budget.

LIFE+ PROGRAM

http://biobale.com/



¿Who participate? COMPANIES:

•Company project coordinator: TUINSA NORTE, SA

•Associated Company: INGENIERÍA Y DISEÑO EUROPEO SA

TECHNOLOGICAL CENTRE:PRODINTEC www.prodintec.es

PUBLIC ORGANISM:NAVIA TOWN COUNCIL www.ayto-navia.es

PARTICIPANTS

www.idesa.net

www.tuinsa.com

http://biobale.com/


http://www.prodintec.es/

http://www.ayto-navia.es/


http://www.idesa.net/

http://www.tuinsa.com/


ORC BIOBALE

ELECTRIC GENERATOR

GENERATOR TYPE Asynchronous

POWER 50 KW

EQUIPMENT DIMENSIONS (WITHOUT CONTAINER)

Lenght x Width x Height 5,2 x 1,5 x 2,2 (meters)

Weight 1800 Kg

http://biobale.com/



ORC BIOBALE

Twin Screw Expander

http://biobale.com/



SOME CONCLUSIONS

ORC is a proven technology for applications such as industrial waste heat

recovery, biomass burning, use of solar heat, geothermal heat sources…

Main advantage compared with a steam cycle is the higher thermal efficiency

when using heat sources at lower temperatures. The ORC is also less

complicated and easier to operate. Occurring pressures are lower.

The classical steam cycle should be considered when sufficient temperature

levels are reachable (fuel burning) combined with turbine scale sizes from about

500 kWe…to 2,5 MWe (to discuss, no clear answer given when to chose an ORC

above a steam cycle)

Excellent combined heat and power capability due to the condenser heat can be

used.

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THANK YOU

どうも有難う御座います

ESKERRIK ASKO

GRACIAS

Adrián Arboleya

[email protected]

For further information

mailto:[email protected]

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