Turn waste heat into value:

the dependable Turboden ORC solutions

Global Cement Waste Heat Recovery Conference and

Exhibition

City of London - Thursday 14th - Friday 15th June 2012

Codice doc. 12-A-347-rev.0

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Agenda

• Company introduction

• ORC based heat recovery plants: main features

• Some reference cases in cement

• Other heat recovery fields

• HREII DEMO: an introduction

• Turboden / PWPS deployment

• Conclusion

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3

Turboden is a leading European company in development and production

of ORC (Organic Rankine Cycle) turbogenerators. This state of the art

equipment generates heat and power from renewable sources and heat

recovery in industrial processes.

The company was founded in 1980 in Milan by Eng. Mario Gaia, former

Professor of Energy at the Polytechnic of Milan, and today the Managing

Director of Turboden. His close connection with the university has always

ensured the recruitment of highly qualified R&D personnel.

Turboden has always had a single mission: design ORC turbogenerators

for the production of heat and electrical power from renewable sources, while

constantly striving to implement ORC technical solutions.

In 2009, Turboden became part of Pratt & Whitney (UTC Corp.), a

worldwide leader in development, production and service for aero engines,

aerospace drive systems and heavy duty gas turbines.

Today Turboden is part of Pratt & Whitney Power Systems (PWPS), to

develop ORC solutions from renewable sources and waste heat worldwide.

Company Introduction

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United Technologies Corporation

4

Research

Center

Hamilton

Sundstrand

Sikorsky UTC Power Otis Carrier UTC

Fire & Security

Large

Engines After

market Marine

Mobile

Power

Fortune 50 corporation

16th largest US manufacturer

$54.3B in 2010 sales

195 countries

210,000 employees

Wind

Power

EPC

Service

ORC

Technology

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standard units from 600 kW to 6 MW

customized solutions up to 15 MW

5

electricity

heat

Biomass

Waste-heat

Geothermal

Solar

What We Do

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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ORC based heat recovery plants

The Thermodynamic Principle of ORC Cycle

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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ORC based heat recovery plants:

Integration scheme to Cement Plant

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ORC based heat recovery plants:

Main advantages

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Presence of an intermediate loop (thermal oil or pressurised water)

• ease of control and operation, even when big fluctuations in primary heat sources

• great layout flexibility

automated and unmanned systems

High molecular weight of organic working fluid • low enthalpy drop across the turbine

• low turbine peripheral speed (low mechanical stress and no reduction gear)

• reduced number of turbine stages

• high mass flow

turbine efficiency > 80 %, good part load efficiencies

No corrosion attitudes of working fluids

long life of the system and low maintenance requirements

Zero Water consumption configuration (option) • no water management activities (pH and salts control, water refilling)

• no water needed

low operation requirements, no water depletion

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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 IV quarter 2010

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Heat Recovery In Cement Production Process

Project Holcim Romania

Reference Case study: PRS and CC gas waste heat recovery

Clinker production capacity: ≈ 4.000 ton/day

Heat source: exhaust gas @ 360°C (PRS) and hot air @ 250 °C (CC)

Thermal oil (PRS) and pressurised water (CC) heat recovery loops

ORC electric power: ca. 4 MWe

Client: Holcim Romania – Holcim Group (Romania)

Under Construction; start up expected in June 2012

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Romania

ORC plant PH boiler AQCboiler

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Heat Recovery In Cement Production Process

Project Holcim Slovakia

Reference Case study: PRS and CC gas waste heat recovery

Clinker production capacity: ≈ 3.600 ton/day

Heat source: exhaust gas @ 360°C (PRS) and hot air @ 310 °C (CC)

Thermal oil heat recovery loops

ORC electric power: ca. 5 MWe

Client: Holcim Slovakia – Holcim Group (Slovakia)

Under Construction; start up expected in II quarter 2013

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Slovakia

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ORC based heat recovery plants:

A first sight to economics

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Total WHRS cost • Influenced by many specific project related factors: size, ambient temperature, exhaust

gas temperatures and flows, number of heat source, layout, electric connection, water

availability, etc.

Total installed cost of 3,000 €/kWnet +/-30% can be used as ball park figure

Financial results are driven by few main factors • WHRS cost

• Electricity value may range between 0,13 €/kWh (e.g. in Italy with White certificates) to

less than 0,05 €

• Operating hrs: the grater, the better (typical values are 7,500 hrs/annum)

• O&M cost: for ORC based plant it’s in the range of 1 % of Capex/year (indicatively half

of steam based plant)

Some examples:

Scenario Best Medium Worst

Capex [€/kW] 2500 3500 4500

Opex [€/kW/y] 35 35 35

Operating hrs 7800 7500 7000

Energy value [€/kWh] 0,12 0,08 0,06

WACC 7% 10% 13%

PBT 3,2 8,7 > 15 yrs

IRR @ 20 year 36% 15% 6%

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GOALs:

a) To realize an integrated fumes depuration and heat recovery system

b) To develop policy and governance actions for reducing CO2

emissions by valorisation of process effluents in Energy Intensive

Industries

For more information: www.hreii.eu/demo

H-REII DEMO Project

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ORC

200 - 900 °C

150 - 350 °C

300 - 1600 °C

Target:

3-5% of the

EAF

installed

power

25%

30% of the

power inserted in the

furnace is lost in the

exhaust

70% of the lost power

could be recovered

Heat recovery from Electric Arc Furnace

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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 - 245°C

Steam available for the ORC unit:

~ 20 t/h of steam at 27 bar and 245°C (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

Heat recovery from Electric Arc Furnace

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EU MSs considered in the analysis: Italy, Germany, France, Spain, UK and Belgium ( 95% of European production in the three areas examined ) + Austria, Czech Rep.

HREII Demo project: first EU estimates

Power to recovery in Europe (first estimation):

630 MWe from 3,2 TWh/y to 5 TWh/y

Steel: 376,6

Cement: 145,8 Glass: 107,1

Total: 629,5

0

100

200

300

400

500

600

700

po

we

r M

W

Sectors

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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

In operation since I quarter 2012

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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 I quarter 2009

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Heat Recovery from Waste Incineration plant

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 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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Turboden strong points

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• 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

• Pre-feasibility

studies: evaluation of

technical &

economical

feasibility of ORC

power plants

• Customized

proposals to

maximize economic

& environmental

targets

• Complete in-house

mechanical design

• Proprietary design

and own

manufacturing of

ORC optimized

turbine

• Tools

- Thermo-fluid-

dynamic programs

- FEA

- 3D CAD-CAM

- Vibration analysis

• Start-up and

commissioning

• Maintenance,

technical assistance

to operation and

spare parts service

• Remote monitoring

& optimization of

plant operation

• Outsourced

components from

highly qualified

suppliers

• Quality assurance &

project management

• In house skid

mounting to

minimize site

activities

R&D Sales/marketing Design Operations &

manufacturing Aftermarket

service

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Turboden – facts & figures

(Last update: February 2012) 22

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Conclusions

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Turboden & PWPS ORC based WHRS for cement • Ease of integration into existing plants

• Very low O&M costs

• Automatic and unmanned operations

• Profitable plants

Optimum solution for industrial users minimising any effect on primary

process

Turboden & PWPS • Have real experience in WHRS in Energy Intensive Industries (Cement, Steel, Glass)

• Can provide customised solutions to meet customers requests

• Have established a network with major stakeholders (WHR exchangers makers, WHR

plant integrators, financing companies and record access to European funds)

The dependable technological partner to successfully exploit WHR

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

Thank you

For more information:

Riccardo Vescovo

Sales Manager Heat Recovery Department

riccardo.vescovo@turboden.it