paolo bertuzzi turboden
TRANSCRIPT
Istanbul, June 25, 2010
Geothermal – Wind – Biomass – Waste Heat
Presented By
Organic Rankine Cycle (ORC)in Biomass application
Paolo Bertuzzi Turboden General Manager – Finance & Commercial Area
2
3
Cogeneration plants with Turboden ORC can produce heat and electrical power from biomass with high efficiency and user friendly operation. The generated power usually ranges between 400 kW and 5 MW electric.
BiomassHeat Recovery Geothermal Solar Thermal Power
Modular ORC Units for biomass applications
Advantages of ORC technology
Technical advantages
Very high turbine efficiency (up to 85%)
Low mechanical stress of the turbine due to the low peripheral speed
Low RPM of the turbine allowing the direct drive of the electric generator without reduction gear
No erosion of blades, no water treatment system due to absence of water
Low mechanical stress of the cycle due to much lower pressure than steam cycle
Operational advantages / results
Automatic and continuous operation
Simple start-stop procedures
No operator attendance needed
High efficiency at partial load and
operation down to 10% of nominal power
Very safe and quiet operation
Low maintenance requirements: planned
maintenance once per year, no major
overhauls
Very High Availability (e.g. Admont, AUT:
operation since 1998, availability > 98%)
Long life – designed for 20+ years
Translate in user advantages
4
RegeneratorCondenser
Feed PumpElectric cubicles
Electric generator
ORC turbine
Modular ORC UnitsLayout Turboden 10
Pre-heater
Evaporator
6
7
CHP UNITS HRS - POWER ONLY UNITS HYBRID SOLUTIONS
Solutions
Modular ORC units for biomass applications
Why Distributed Biomass-Fueled CHP?
sustainable & renewable: CO2 neutral and re-growing fuel
local energy source: no dependence on volatile global fossil fuel markets
local base-load electric power: relief for congested transmission lines
impact on economy: uses a local supply chain and keeps energy revenues local
clean technology: small plants - easier permit
9
Graph source: “Der biologische geschlossene Kreislauf” www.biomasseverband.it (April 2010)
Biomass Energy: Centralized Electric Power
10
Graph source: Neil Harrison: „Wood burns: an urban myth?“ Presentation held at „International Biomass Conference“, Portland, OR, 2009
optimized electric efficiency low total energy efficiency (< 40%; no use of heat) higher biomass transport cost & transmission losses
Biomass Energy: Distributed CHP
11
Graph source: Neil Harrison: „Wood burns: an urban myth?“ Presentation held at „International Biomass Conference“, Portland, OR, 2009
very high total energy efficiency (CHP) higher specific investment cost low biomass transport cost & transmission losses
ORC Plants – Perfomances
100 %
20 %
2 %
78%
Thermal power from thermal oil
Thermal power to heat users
Thermal losses (insulation and generator losses)
12
Gross electric power
Gross electric efficiency: nearly 20%
Overall energy efficiency: 98%
Combined Heat & Power (CHP) without Split System
13
TURBODEN 4 CHP
TURBODEN 6 CHP
TURBODEN 7 CHP
TURBODEN 10 CHP
TURBODEN 14 CHP
TURBODEN 18 CHP
TURBODEN 22 CHP
INPUT - Thermal oilNominal temperature (in) °C 300 300 300 300 300 300 300Nominal temperature (out) °C 240 240 240 240 240 240 240Thermal power input kW 2300 3240 3815 5140 6715 9790 12020OUTPUT - Hot waterHot water temperature (in/out) °C 60/80 60/80 60/80 60/80 60/80 60/90 60/90Thermal power to the cooling water circuit kW 1854 2565 3038 4081 5313 7834 9601PERFORMANCESGross active electric power kW 427 641 737 1016 1339 1863 2304Gross electric efficiency 0,186 0,198 0,193 0,198 0,199 0,190 0,192Captive power consumption kW 21 30 35 48 58 79 97Net active electric power kW 406 611 702 968 1281 1784 2207Net electric efficiency 0,177 0,189 0,184 0,188 0,191 0,182 0,184
Plant size Single Skid Single Skid Single Skid Multiple Skid Multiple Skid Multiple Skid Multiple SkidBiomass consumption* Kg/h 1106 1558 1834 2471 3228 4707 5779
asynchronous triphase, L.V.
400V
asynchronous triphase, L.V.660V
*Assuming a low heat value of biomass = 2,6 kWh/kg and boiler efficiency = 0,80. The thermal oil boiler is not included in the Turboden scope of supply.
Combined Heat & Power (CHP) - Standard Sizes and typical performances
Electrical generatorasynchronous triphase, L.V.
400V
asynchronous triphase, L.V.
400V
asynchronous triphase, L.V.
400V
asynchronous triphase, L.V.
400V
asynchronous triphase, L.V.
660V
Combined Heat & Power (CHP) with Split System
14
TURBODEN 4 CHP
TURBODEN 6 CHP
TURBODEN 7 CHP
TURBODEN 10 CHP
TURBODEN 14 CHP
TURBODEN 18 CHP
TURBODEN 22 CHP
“split” “split” “split” “split” “split” “split” “split”
Nominal temperature "HT" loop (in/out) °C 310/250 310/250 310/250 310/250 310/250 312/252 312/252Thermal power input "HT" loop kW 2100 2965 3485 4690 6130 8935 10975Nominal temperature "LT" loop (in/out) °C 250/130 250/130 250/130 250/130 250/130 252/132 252/132Thermal power input "LT" loop kW 200 275 330 450 585 855 1045Overall thermal input kW 2300 3240 3815 5140 6715 9790 12020
Hot water temperature (in/out) °C 60/80 60/80 60/80 60/80 60/80 60/90 60/90Thermal power to the cooling water circuit kW 1844 2600 3060 4100 5350 7850 9630
Gross active electric power kW 424 617 727 1001 1317 1862 2282Gross electric efficiency 0,184 0,19 0,191 0,194 0,196 0,19 0,189Captive power consumption kW 24 30 38 51 62 87 107Net active electric power kW 400 587 689 950 1255 1775 2175Net electric efficiency 0,174 0,181 0,181 0,184 0,186 0,181 0,181
asynchronous asynchronous asynchronous asynchronous asynchronous asynchronous asynchronoustriphase, L.V.
400Vtriphase, L.V.
400Vtriphase, L.V.
400Vtriphase, L.V.
400Vtriphase, L.V.
400Vtriphase, L.V.
660Vtriphase, L.V.
660V
Plant size Single Skid Single Skid Single Skid Single Skid Multiple Skid Multiple Skid Multiple SkidBiomass consumption** Kg/h 1005 1416 1667 2247 2935 4279 5254* The Turboden split system allows maximising electric power production for a given biomass consumption. **Assuming a low heat value of biomass = 2,6 kWh/kg and boiler efficiency = 0,88 . The thermal oil boiler is not included in the Turboden scope of supply.
Combined Heat & Power (CHP) with split - Standard Sizes and typical performances *
INPUT - Thermal oil
OUTPUT - Hot water
PERFORMANCES
Electrical generator
Biomass – Fuels & Applications
FUELS Wood biomass:
sawdust, woodchips, bark, treated wood
Other biomass: dried sewage sludge, straw, green cuttings,rice husk
Waste material
Waste recycling wood
APPLICATIONS
Timber drying in sawmills
Saw dust drying in wood pellet factories
Air pre-heatingin MDF industry
District Heating networks
Refrigeration /air conditioning
Turboden standard unit
CHP for cogeneration
and/or trigeneration
Up to 20% efficiency
15
ORC Application in Sawmills
hotwate
r
SELECTION
DRYINGPACKAGING
TRUNKS
PRODUCT
bark sawdust
BARKING PROCESSING cold water
ELECTRICPOWER
Thermal
oilBIOMASSPOWERED
BOILER
ORC
16
Saw Mill ‘Mayr-Melnhof in Leoben (Austria)
17
Biomass-fueled thermal oil boiler:32,5 MW biomass input power - 28 MW thermal oil output powerThermal oil temperature 300°C (572°F)
3 x Turboden 1,5 MWe units: el. capacity 4,5 MWe - annual electricity production: 36 GWh
hot water capacity: 23 MWth - annual heat production (hot water @ 95°C (203°F)): 192 GWh y 650 000 MMBtu
Heat users:Lumber drying kilnsPellet plant (75 000 t/year)Office space heating
Started up: April 2005
CHP Applications: Wood Pellet Production with ORC
CHIPPING
COOLINGPELLET MAKING PRESS
DEDUSTING SELECTION REFINING
DRYING
TRUNKS
pellets
READY PELLETS
Thermaloil
Electric power
hot water
BIOMASSPOWERED
BOILERORC
BARKING
SELECTION
WOOD CHIPS
coldwater
18
Case study – Pellet application
19
Customer: Bio-Energie Mudau GmbH & Co. KGLocation: Mudau - GermanyStart up: October 2006Model: T1100 CHPElectric Power: 1100 kWThermal Power to the cooling water circuit: 5335 kW Water Temperature (in/out): 60°- 85°CFuel: woodchipApplication: Pellet
CHP – District Heating Networks
WITHOUT ORC
WITH ORC
HEAT USER
BIOMASS POWERED
BOILERBIOMASS
hot water
coldwate
r
HEAT USER
BIOMASS coldwate
rhot water
BIOMASS POWERED
BOILER Thermal
oil
Electric power
ORC
20
Case study – District heating application
21
Customer: T.C.V.V.V. SpaLocation: Tirano (SO) ItalyStarted up: June 2003Model: T1100 CHPElectric Power: 1.1 MWThermal Power to the cooling water circuit: 4.8 MW Water Temperature (in/out): 60°- 80°CFuel: woodchipApplication: District heating network
Biomass CHP District Heating in Vipiteno (Italy)
District heating network length 45 km with 750 connections
Regular winter heat demand: 12-14 MW with peaks up to 22 MW thermal
Baseload installations: Biomass thermal oil boiler (7 MW thermal) Turboden ORC unit:
electric capacity: 1,2 MWe hot water capacity: 5,5 MW
Additional peaking installations: 8,6 MW biomass water boiler 8 MW hot water storage
Back-up boiler 9 MW fuel oil boiler
22
Started up: January 2008
The District Heating Model in Central Europe
Small and medium-size communities (typically 2000-10000 inhabitants) Starting point: main heat users as community buildings, school/college,
hospital, large commercial & industrial users Small residential users can follow Modern hot water piping infrastructure has a life time of 40-50 years Strong regional policy support for sustainable development:
Investment incentives depending on region Long-term feed-in rates for electricity from biomass
Financial/Investment schemes: Local utilities Co-ops with farmers, forest owners & communities Local private long-term thinking investors
23
Case study – Industrial process application
24
Customer: Parboriz SpaLocation: Mortara (PV) ItalyStarted up: July 2008Model: T600 CHPElectric Power: 600 kWThermal Power to the cooling water circuit: 2.8 MW Water Temperature (in/out): 60°- 80°CFuel: rice huskApplication: Industrial process (production of parboiled rice)
25
Customer: MDF Hallein GmbH & Co KGLocation: Hallein AustriaStarted up: Nov 2005Model: T1500 CHPElectric Power: 1500 kWeThermal Power to the cooling water circuit: 7100kWthWater Temperature (in/out): 60°- 90°CFuel: waste biomass from the processApplication: Industrial process (production of MDF panels)
Case study – MDF application
26
CHP UNITS HRS - POWER ONLY UNITS HYBRID SOLUTIONS
Solutions
Modular ORC units for biomass applications
HRS for electricity generation and cogeneration from biomass
Gross performance of the Turboden HRS modules at various condensation water temperatures
27
HRS – High electrical efficiency units
TURBODEN 12 and 24 HRS for BIOMASS application
28
HRS – High electrical efficiency units
Fuels & Applications
FUELS Wood biomass:
sawdust, woodchips, bark, treated wood
Other biomass: dried sewage sludge, straw, green cuttings,rice husk
Waste material
Waste recycling wood
APPLICATIONS
Greenhouses
Swimming pool
Thermal bath
No thermal users
Turboden standard unit
HRS(power only)
Up to 24% efficiency
30
31
Case study – HRS woodchips plant in southern Italy
Customer: Fiusis s.r.lLocation: Calimera (Lecce) - ItalyStart-up: 3rd quarter 2010Model: Turboden 12 HRSElectric Power: 999 kWeThermal Power to the cooling water circuit: 4500 kWthWater Temperature (in/out): 25°- 35°CFuel: woodchips (mainly from olive trees)Application: power production from woodchips
The Italian newspaper Il Sole 24 Ore issued an article on this plant
32
CHP UNITS HRS - POWER ONLY UNITS HYBRID SOLUTIONS
Solutions
Modular ORC units for biomass applications
Solar thermal power technology
Parabolic trough system
ENEA collectors
Solar Millenium collectors
Solel collectors
34
Poin focal solar power tower
Solar Two, California
PS 10, Seville
Solar thermal power technology
35
Case Study – Hybrid Solar Thermal Power Plant
hot thermal oil
cold thermal oil
electric power output
Fig.: Simplified configuration diagram of an ORC hybrid solar thermal power plant
36
0
1000
2000
3000
4000
5000
6000
7000
8000 Th. Power from SUN Th. Power from BIOMASS Th. Power to ORC Th. Power from STORAGE
Ther
mal
pow
er [k
W]
day 1 day 2 day 3 day 4 day 5 day 6 day 7
Simulation Software:
power input in a one week time
Case Study – Hybrid Solar Thermal Power Plant
37
Fig.: Preliminary layout out of a hybrid solar thermal power plant using Turboden 12 HRS
Power output: 1 MWel
Case Study – Hybrid Solar Thermal Power Plant
38
Case study for biomass
Analysis of a co-generative biomass plant (Turboden CHP 22 split) and of a dissipative biomass plant (Turboden
HRS 24 split)
39
Analysis for Turkish market: Hypotheses
40
Input parameters
Electric energy cost 0,09 €/kWh
Thermal energy cost 0,03 €/kWh
Plant own consumption (ORC excluded) 250 kWel
Interest rate 5 %
ORC maintenance costs 15.000 €/year
The study analyze two different cases:• Turboden 22 CHP split and Turboden 24 HRS split; Variable biomass
cost (up to 50 €/t), variable feed in tariff;• Turboden 22 CHP split and Turboden 24 HRS split; Fixed feed in
tariff (0,14 €/kWh), variable cost of biomass.
41
Cogeneration with Turboden 22 CHP
Boiler thermal power 12.020 kWth
Nominal power at the furnace* 13.659 kWth
Net electric power from ORC 2.282 kWel
Thermal power to the grid (at 85 °C) 9.630 kWth
Portion of thermal energy sold** 50%
Plant own consumption (estimation) 250 kWel
Yearly biomass consumption*** 36 ktons
Net electrical power to the grid 2.032 kWel
Total investment (estimation) 7.900.000 €
ORC cost 2.050.000 €
Analysis for Turkish market: Hypotheses
* Assuming 88% boiler performance ** Assuming 8.000 working hours a year, the overall thermal power produced results in 77 MWh a year; it is assumed that 50% (equivalent to 4.000 hours a year – i.e. 38,5 MWh) is sold and 50% dissipated *** Assuming 3 kWh/kg biomass low heat value
42
Cogeneration with Turboden 24 HRS
Boiler thermal power 9.634 kWth
Nominal power at the furnace* 10.948 kWth
Net electric power from ORC 2.269 kWel
Thermal power dissipated** 7.212 kWth
Plant own consumption (estimation) 250 kWel
Yearly biomass consumption*** 29 Ktons
Net electrical power to the grid 2.019 kWel
Total investment (estimation) 8.200.000 €
ORC cost 2.150.000 €
Analysis for Turkish market: Hypotheses
* Assuming 88% boiler performance** Assuming 8.000 working hours a year, the overall thermal power to be dissipated in one year results in 58 MWh*** Assuming 3 kWh/kg biomass low heat value
Turkish example: with feed in tariff (0.14 €/kWh)
43
0 5 10 15 20 25 30 35 40 45 502.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
22 CHP split24 HRS split
Biomass Cost (€/t)
Pa
yb
ac
k T
ime
(y
ea
rs)
Turkish example: Incentive vs Biomass cost
44
0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22 0.242.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
22 CHP split
0 €/t10 €/t20 €/t30 €/t40 €/t50 €/t
Tariff (€/kWh)
Pa
yb
ac
k T
ime
(y
ea
rs)
Tariff
Tariff currently under discussion*
* Source: Platts Renewable Energies Report - Nov. 2009
Turkish example: Incentive vs Biomass cost
45
0.10 0.12 0.14 0.16 0.18 0.20 0.22 0.242.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
24 HRS split
0 €/t10 €/t20 €/t30 €/t40 €/t50 €/t
Tariff (€/kWh)
Pa
yb
ac
k T
ime
(y
ea
rs)
Tariff
Tariff currently under discussion*
* Source: Platts Renewable Energies Report - Nov. 2009
PWPS/Turboden contacts:
Kor Kurt AKIN
Senior Partner Turkiye, Russia, Caucasus & Middle East
Transnational Venture Consultants
Pratt & Whitney Power Systems and Turboden Sales Representatives for ORC machines in Turkey
Alessandro Guercio
Sales Manager Biomass Department at Turboden
Please contact us!
46
Thanks for your attention!