Turboden ORC plants for Industrial Heat RecoveryThe proven way to address environmental sustainability

Codice doc. 11-COM.P-9-rev.3

Update: 1/04/2011

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About us – A Pratt & Whitney Power Systems Company

Research

Center

Hamilton

Sundstrand

Pratt & Whitney

SikorskyUTC Power OtisCarrierUTC

Fire & Security

Fortune 50 corporation$52.9B in 2009 sales

180 countries206,700 employees

Large

Engines

Small

Engines

After

marketMarine

Mobile

Power

Heat to Electricity

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Pratt & Whitney, a division of United Technologies Corporation (UTC), is a

world leader in the design, manufacture and service of aircraft engines,

industrial gas turbines and space propulsion systems.

Pratt & Whitney Power Systems (PWPS), the industrial gas turbine business

of Pratt & Whitney, provides power generation and mechanical drive solutions

for the electric generation, oil and gas markets, including service through the

entire product life cycle

PWPS also manufactures and markets the PureCycle® system that can

harness heat in the form of hot water from many different sources such as

geothermal or oil & gas co-produced fluids, reciprocating engines, and

industrial waste heat to generate clean and reliable electricity.

Turboden, a Pratt & Whitney Power Systems company, is a European leader

in ORC technology for the generation and cogeneration of heat and power from

renewable energy and heat recovery.

• operating profit of $1.99 billion in 2010

• revenues of $12.94 billion

• 36,000 employees

• more than 11,000 customers

• 195 countries

About us – A Pratt & Whitney Power Systems Company

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Turboden – What We Do

•standard size Turbogenerators from 200 kWel to 3 MWel

• customized products up to 15 MWel

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.

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Turboden - 30 Years of Experience

1984: A 40 kWel ORC turbogenerator for a

solar application in Perth, Australia

1987: A 3 kWel CHP biomass ORC turbo-

generator plant in Milan

2008: A 3 MWel ORC turbogenerator for waste heat in Belgium

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The Turboden ORC Turbogenerator

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ORC is a commercial

technology for

distributed production

of combined heat and

power from various

renewable energy

sources

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The Thermodynamic Principle: The ORC Cycle

TE

MP

ER

AT

UR

E

ENTROPY

WATER

THERMAL

OIL

THERMAL OIL

Evaporator

Pump

Condenser

WATER

Regenerator

Generator

The turbogenerator uses the hot temperature thermal oil to pre-heat and vaporize a suitable organic working

fluid in the evaporator (8 3 4). The organic fluid vapor powers the turbine (4 5), which is directly coupled to the

electric generator through an elastic coupling. The exhaust vapor flows through the regenerator (5 9) where it

heats the organic liquid (2 8). The vapor is then condensed in the condenser (cooled by the water flow) (9 6

1). The organic fluid liquid is finally pumped (1 2) to the regenerator and then to the evaporator, thus

completing the sequence of operations in the closed-loop circuit.

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Advantages of Turboden ORC Turbogenerators

Technical advantages

High cycle efficiency

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, thanks to the

absence of moisture in the vapor nozzles

Operational advantages / results

Simple start-stop procedures

Automatic and continuous operation

No operator attendance needed

Quiet operation

Very High Availability (Admont – over

50,000 hours of operation, availability >

98%)

Partial load operation down to 10% of

nominal power

High efficiency even at partial load

Low O&M requirements: about 3-5 hours /

week

Long life

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Layout – Some Examples

TURBODEN 7 layout

TURBODEN 18 layout

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Layout – Some Examples

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ORC Applications – Heat Recovery

Heat Recovery

Turboden ORCs 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 400 kW and 5 MW electric.

Biomass Heat Recovery Geothermal Solar Thermal

Power

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HR – Applications / Energy 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 materials furnaces

exhaust gas

Exhaust Gas from waste incineration (civil/industrial)

Gaseous sources:

Liquid sources:

Condensing

sources:

Refineries hot streams

Cooling water (or other fluids) loops in industrial

processes

Jacket cooling water of reciprocating engines

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)

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HR (Heat Recovery) modules

Standard Sizes and Typical Performances

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Modules with power outputs above 3 MW are optimised case by case

TURBODEN

6 HR

TURBODEN

7 HR

TURBODEN

10 HR

TURBODEN

14 HR

TURBODEN

18 HR

TURBODEN

22 HR

INPUT - Thermal oil

Thermal oil nominal

temperature (in/out)°C 260 / 150 270 / 150 270 / 150 275 / 150 280 / 150 280 / 150

Thermal power input kW 2.970 3.600 4.880 6.700 9.000 11.400

OUTPUT - Cooling water

Cooling water temperature

(in/out)°C

25 / 35 25 / 35 25 / 35 25 / 38 25 / 40 25 / 44

Thermal power to the

cooling water kW 2.340 2.840 3.840 5.275 7.065 9.000

Performances

Gross electric power kW 600 726 1.000 1.370 1.848 2.296

Gross electric efficiency 20,2% 20,2% 20,5% 20,4% 20,5% 20,1%

Captive power consumption kW 25 30 38 52 60 76

Net active electric power

output kW 575 696 962 1.318 1.788 2.220

Net electric efficiency 19,4% 19,3% 19,7% 19,7% 19,9% 19,5%

Electrical generator

asynch., 3

phase, L.V.

asynch., 3

phase, L.V.

asynch., 3

phase, L.V.

asynch., 3

phase, L.V.

asynch., 3

phase, L.V.

asynch., 3

phase, L.V.

m 15 X 3 X 3,1 15 X 3 X 3,1 15 X 6 X 3,3 13 X 6 X 6,2 15 X 7 X 5 17 X 7 X 5

Single skid Single skid Single skid Multiple skid Multiple skid Multiple skidSize of plant

*Data indicated could change taking into account the actual features of the specific project (optimization of heat recovery application).

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Heat recovery from Internal Combustion

Engines: heat sources

Exhaust gas: Typically contains between 1/4 and 1/3 of the fuel heat, being released at relatively high temperatures (300 500 C).

ORC production reaches up to 10% of engine power output

Jacket water: very low temperature heat (< 100 C) is released by this loop to atmosphere.ORC production (including main plant savings) reaches up to 3 % of engine power output

Turboden's ORC modules for heat recovery have a power output between 400 kWe up to 10 MWe: the minimum thermal power necessary to employ a Turboden ORC is approximately 2 MWt

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Project ORC Module Site Engines

Pisticci I TURBODEN 18 HR SPLIT (1,8 MWe)In operation since IV quarter 2010

Pisticci (I) 3 x 8 MWe Wartsila Diesel engines

Oxon TURBODEN 6 HR SPLIT (0,6 MWe)In operation since IV quarter 2008

Pavia (I) 1 x 8 MWe MAN Diesel engine

FinPower TURBODEN 6 HR DIR. EXCH. (0,6 MWe)In operation since II quarter 2009

Visano (I) 1 x 17 MWe Wartsila Diesel engine

Pisticci II TURBODEN 40 HR SPLIT (3,8 MWe)Under construction

Pisticci (I) 3 x 17 MWe Wartsila Diesel engines

Cereal Docks TURBODEN 6 HR DIR. EXCH. (0,6 MWe)Under construction

Portogruaro (I) 1 x 7 MWe Wartsila Diesel engine

Eukrasia TURBODEN 6 HR SPLIT (0,6 MWe)In operation since II quarter 2010

Catania (I)2 x 1 MWe JGS/GE gas engine + 3 x 0,8 MWe JGS/GE gas engine + 1 x 0,6 MWe JGS/GE gas engine

Blue TowerTURBODEN 6 HR (0,6 MWe)Under construction

Herten (D) 2 x 2,1 MWe MWM gas engine(+ additional heat from the process)

UlmTURBODEN 10 HR cogenerative (1 MWe)Under construction

Senden (D) 2 x 2 JGS/GE gas engine(+ additional heat from the process)

KempenTURBODEN 6 HR cogenerative (0,6 MWe)Under construction

Kempen (D) Diesel engine

MondopowerTURBODEN 10 HR (1 MWe)Under construction

Chivasso (I) 1 x 17 MWe Wartsila Diesel engine

HSY TURBODEN 14 HR (1,3 MWe)Under construction

Ämmässuo (FIN) 4 x 4 MWe MWM gas engines

Heat Recovery from Internal Combustion

Engines: reference projects

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Heat Recovery from Gas Turbine: 20% add’l

power / reduction in specific emissions

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Centaur 40 Solar

SGT-200 Siemens

Mars 100 SolarTitan 130 Solar

LM2500 GEFT 8 P&W

UGT 25000 ZoyraRB211 RR

0%

10%

20%

30%

40%

50%

60%

70%

80%

0

1.000

2.000

3.000

4.000

5.000

6.000

7.000

8.000

9.000

0 5.000 10.000 15.000 20.000 25.000 30.000

OR

C G

ross

Po

we

r O

utp

ut

[kW

]

Gas Turbine Shaft Power Output [kW]

TURBODEN ORCs Power output vs Gas Turbine Shaft Power Output

Pel ORC % Pel ORC/Pel Gas Turbine

SGT-500 Siemens

SGT-700 Siemens

ORC suitable for heat recovery in:

Remote/unmanned locations with variable operating loads (e.g. gas compressor stations)

“Peak load” power stations (easy and fast start-up procedures)

Heavy duty / continuous applications

NOTE: Indicative values assuming ambient air temperature of 15°C, Gas Turbines operating at nominal load;

calculations based on Gas Turbine exhaust gas properties as reported in specific suppliers web sites.

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Reference Case Study:

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

Under construction, start up 1st quarter 2011

Heat Recovery from Gas Turbine

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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.

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Heat Recovery In Cement Production Process

Reference Case study: PRS gas waste heat recovery

Clinker production capacity: ≈ 5.000 ton/day

Heat source: exhaust gas @ 330°C

Gas cooled down to 220°C (extra heat used for raw

material pre heating)

ORC electric power: ca. 2 MWe

Client: CIMAR – ITALCEMENTI GROUP (Morocco)

In operation since 2nd quarter 2010

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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 @ 500 °C

Gas cooled down to ca. 150 °C

ORC electric power: ca. 1 MWe

Client: RHI GROUP (Radenthein - Austria)

In operation since: first quarter 2009

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Heat Recovery in Steel Industry

Rolling, forging

Strip processing

Heat treatment

BOF

Blast furnaces

Sinter

Electric Arc Furnace

Main exhaust gas streams available:

Relatively clean exhaust gas at moderate

temperature

Cost effective for ORC ≥ 600/800 kWe

Exhaust gas: high flows, high temperatures,

high dust content, large variations in operating

cycle, environmental constraints

Interface between process and energy

recovery unit is critical

ORCs proposed where heat recovery

exchangers are available

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Heat Recovery in Glass Industry

High exhaust gas temperature

Constant operating conditions

Exhaust gas with moderate dust content

Exhaust gas must be cooled not below 200°C

Heat source main properties:

High temperature ORC cycle employed:

ORC electrical efficiency up to 25 %

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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 500°C

ORC electric power: ca. 1,3 MWe

Final Client: AGC Glass Europe – Cuneo Plant

General contractor: GEA Bischoff

Under construction, start up 4nd quarter 2011

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Heat Recovery from Hot Liquid streams

Thermal power in hot liquids streams can be used

directly as input to the ORC unit

Cost-effective plants with ORC power greater than

1.000 kWe and liquid temperature higher than 100-120 °C

Solutions studied and optimised case-by-case.

Power Output > 1 MWe:

Turboden tailor made

ORC plants

Power Output < 1 MWe

Pratt and Whitney

PureCycle®

Modular/scalable 270 kWe ORC unit: PureCycle®

Cost-effective plants starting from single 270 kWe

PureCycle® unit (reduced investment costs)

Three standard cycles to match heat sources

(water, etc.) temperatures between 90 °C and 150 °C

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Heat Recovery – Reference Case study

Plant type:

Heat recovery from pressurized

water boiler in waste incinerator

Customer :

MIROM (Roeselare-Belgium)

In operation since:

2nd quarter 2008

Heat source:

hot water at 180 C (back 140 C)

Cooling source:

water/air

Total electric power:

3 MWel

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)

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The PureCycle® Power System

• 280 kW Gross Power

• Free fuel

• Zero emissions

• Renewable baseload power generation

• 195°F – 300°F resource range

• Modular and scalable for larger plants

• Short lead times

• 24/7/365 remote monitoring

• High availability

* 91ºC – 149ºC

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Cooling Tower

• Commissioned December 2008

• Operating on jacket water of 10MW reciprocating engine ~ 200kW net

• Displaces expensive fuel costs

• Supports green initiative of customer

Heat Recovery – Reference Example

Example of PureCycle® unit in operation: heat recovery

from reciprocating engine in Guatemala

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Heat Recovery Data Collection Sheet

Title: Heat recovery data collection sheet

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

(*)T-2Temperature:

………

….. °C

(*)T-3Flow rate:

………

….. kg/s ………………………. Nm3/hr

T-4Heat source characteristics

T-4aComposition:

CO2 ………… %

CO ………… %

H2O ………… %

N2 ………… %

Other (…………) ………… %

Other (…………) ………… %

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)

T-11Other notes:

………………………………………………………………………………………….

………………………………………………………………………………………….

………………………………………………………………………………………….

………………………………………………………………………………………….

………………………………………………………………………………………….

………………………………………………………………………………………….

………………………………………………………………………………………….

………………………………………………………………………………………….

………………………………………………………………………………………….

Economical data

(*)E-1Operating time: ………………….. hours/day

………………….. hours/year

E-3Energy sources:

E-3aElectricity:

Average cost: ………………….. €/MWh

E-3bMethane / natural gas:

Yearly consumption: …………………… Nm3

E-3cOther fuels: ………………………………………….

Yearly consumption: …………………… [………………]

Average cost: ………………….. [€ / …………...]

E-4Possible co-generative use:

temperatures: …………/………… °C

Additional notes: ……………………………………………..

……………………………………………..

……………………………………………..

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Turboden at a Glance

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Turboden at a Glance

R&D

Participation in national &

EU research programs

Cooperation with EU

Universities and Research

Centres

Thermodynamic cycle

optimization

Working fluid selection &

testing

Thermo-fluid-dynamic

design and validation

Implementation & testing of

control/supervision software

Many patents obtained

MARKETING/SALES

Evaluation of technical

& economical feasibility

of ORC power plants

Customized proposals

to maximize economic &

environmental targets

Support for applications

to Public Authorities for

Green Power incentives

DESIGN

Complete in-house

mechanical design

Proprietary design

and own

manufacturing of ORC

optimized turbine

TOOLS

• Thermo-fluid-

dynamic programs

• FEA - Finite Element

Analysis

• 3D CAD-CAM

• Vibration analysis

SERVICE

Start-up and

commissioning

Maintenance,

technical assistance to

operation and spare

parts service

Remote monitoring &

optimization of plant

operation

OPERATION &

MANUFACTURING

Outsourced

components from

highly qualified

suppliers

Quality assurance

& Project

management

In house skid

mounting to minimize

site activities

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Turboden – Facts & Figures

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(Last update: January 2010)

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Notes

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Notes

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Notes

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Turboden s.r.l.

Via Cernaia, 10 - 25124 Brescia, Italia

tel +390303552001 - fax +390303552011

info@turboden.it www.turboden.it

C.F./P.I. IT02582620981

capitale sociale €1.800.000 i.v.

R.I.: C.C.I.A.A. di Brescia 02582620981

REA 461817