waste heat recovery in energy intensive industries 2012
TRANSCRIPT
Final Event - Webinar October 6, 2014
Waste Heat Recovery in Energy Intensive Industries
2012-2014 Project Results
Final Event - Webinar October 6, 2014
Marco Baresi – H-REII DEMO Project Manager
Marco Taesi – Feralpi Group
Simone Castrini – Comeca
Francesco Campana – Turboden
Daniele Forni – FIRE Waste Heat Recovery In Energy Intensive Industries
2012-2014 Project Results
Partners
Turboden, a Mitsubishi Heavy Industries company, is a global leader in the design, manufacture and
service of Organic Rankine Cycle (ORC) turbogenerators, which harness heat to generate electric and
thermal power from renewable sources (biomass, geothermal, solar energy) and waste heat from
industrial processes, engines and gas turbines. Turboden has about 290 plants in 32 countries and
offers turbogenerators from 200 kWel to 15 MWel.
CO.ME.CA. S.p.A. has been operating in the mechanical structural steel work field for the iron and
steel industry since 1969. Since the very beginning, the company has continuously updated its in-
house machinery, technologies and machining processes to state-of-the-art levels, with the maximum
satisfaction of all its customers in mind. The experience of its highly specialized technical personnel
has made CO.ME.C.A. S.p.A. one of the most qualified and appreciated suppliers in its sector.
FIRE (Italian Federation for Energy Efficiency) is a non-profit organization established in 1988 to
promote the efficient use of energy. Since 1992 FIRE manages the Italian energy manager network
on behalf of the Ministry of Economic Development, promoting their role through various initiatives.
FIRE also encourages in collaboration with the relevant institutions a positive development of the
legislative and regulatory framework in order to foster an efficient use of energy.
Agenda
Why the H-REII Demo
Technical aspects
the overall concept
the heat exchanger
the ORC
Policy, regulatory aspects and dissemination
Agenda
Why the H-REII Demo
Marco Baresi - HREII-DEMO Project Manager
Technical aspects
the overall concept
the heat exchanger
the ORC
Policy, regulatory aspects and dissemination
Heat Recovery in Energy Intensive Industries
… the policy project !
quantify the potential heat recovery for electricity
generation in the Italian EIIs (pilot model)
energy audits in EIIs: 49 in Italy, 50 in Austria
promote energy efficiency policy in Italy
training and dissemination
Turboden technology
CSMT scientific
FIRE scientific
Confindustria institutional
Provincia di Brescia institutional
H-REII experience 2010-2012
Heat Recovery in Energy Intensive Industries
… the demonstration project !
support demonstration of ORC heat recovery plant in
the Steel Industry
quantify the potential in the European EIIs
promote energy efficiency policy in Europe
(disseminating best practice)
training and dissemination
Turboden technology
Comeca technology
FIRE scientific
H-REII became DEMO 2012-2014
Waste Heat Recovery
Electric Arc Furnace
(EAF)
Heat exchangers
+ Steam drum
Industrial thermal user
Exhaust gases
Organic Rankine
Cycle
Electric energy
Reducing consumption
World first
demonstrative plant
at ESF Feralpi
Riesa, Germany
in operation since
Dec. 2013
Agenda
Why the H-REII Demo
Technical aspects
the overall concept
Marco Taesi – Feralpi Group
the heat exchanger
the ORC
Policy, regulatory aspects and dissemination
Elbe Stahlwerke Feralpi Riesa, Germany
The Group has 1,300 employees in Italy and other EU countries. Present in Germany since 1992
(with ESF Elbe-Stahlwerke Feralpi GmbH in Riesa), also operates in the Czech Republic and
Hungary.
Feralpi continues pursue investment programs aimed at technological innovation and boosting
production efficiency, a means to minimize costs and increase its competitive edge.
The Feralpi Group was founded in
1968 and is recognized as a leading
European manufacturer of iron and
steel, especially steels for the building
industry. In 2013, the Group achieved
a consolidated turnover of € 944 mln,
and turned out:
1.9 million tonnes of steel in billets,
1.7 mln ton of finished products and
0.57 mln ton of cold-rolled products.
Elbe Stahlwerke Feralpi Germany: Product and technology
ESF Elbe-Stahlwerke Feralpi GmbH produces reinforcing steel in the form of bars and coils
Steel shop for steel billets as semi-finished product (up to 1 million tons of steel billets)
Hot rolling mill (up to 0.8 million tons of reinforcing steel per year)
In Riesa the steel production activity has a long tradition: since 1843.
From 2012 ESF has been certified with EMAS (Eco Management and Audit Scheme).
Drivers to project development
The companies in the Feralpi Group collaborate with independent agencies on several scientific
research projects.
Most of the programs cover several years and, due to their importance, Feralpi benefits from
European and domestic public grants, and is considered a benchmark for best practice in a
number of areas, such as de-dusting technology, reducing CO2 emissions and effective
management of the electric furnace charge mix.
Of particular interest is the HREII-Demo project, which was launched in Riesa in 2012 and has
developed a highly innovative technology to recover steam from the mill’s electric furnace, which
would otherwise be dispersed into the atmosphere in the form of water vapor.
H-REII Demo – the plant
Heat to power system Industrial heat recovery source
Power
Cooling system
Heat carrier loop Saturated steam
Thermal user
Local Municipality
Steam and condensate return pipeline
Distance between steel shop and thermal user: 0.8 miles
ESF: Waste Heat to Power layout
0
ORC Unit
Steel Shop
0
Thermal user: tire plant
Waste Heat Boiler
Evaporative Cooling System
Local Municipality
Steam and condensate return pipeline
Distance between steel shop and thermal user: 0.8 miles
ESF: Waste Heat to Power layout
0
ORC Unit
Steel Shop
0
Thermal user: tire plant
Waste Heat Boiler
Evaporative Cooling System
Local Municipality
Project Focus
Agenda
Why the H-REII Demo
Technical aspects
the overall concept
the heat exchanger
Simone Castrini– Comeca
the ORC
Policy, regulatory aspects and dissemination
EAF
Heat Exchangers
Thermal user ORC
Thermal users
Electricity
Water cooling
Electricity + Fossil Fuels
+ Metal Oxidation
Electric Arc
Furnaces
Metal Scrap Melting
Fumes
ORC
Losses
Radiation
Heat
Exchanger
Steam
Steam
accumulator
Fumes
Steam
Fumes
Baghouse
Filter
Steam
Convective
Heat
Exchanger
Stack
Steam
EAF Heat Recovery: Heat exchangers
H-REII Demo – Technical detail
Evaporative Cooling System – Reference plant Georgsmarienhütte GmbH
H-REII Demo – Technical detail
Tenova Evaporative Cooling System Comeca Waste Heat Recovery (Co-designed with Tenova) + Turboden ORC
H-REII Demo – Technical detail
Tenova Evaporative Cooling System Comeca Waste Heat Recovery (Co-designed with Tenova) + Turboden ORC
innovation
EAF
Heat Exchangers
Thermal user ORC
EAF Heat Recovery: Heat exchangers
1. Radiation heat exchanger 2. Convective heat exchanger
3. Steam drum 4. Steam accumulator Courtesy of
EAF
Heat Exchangers
Thermal user ORC
EAF Heat Recovery: Heat exchangers
1. Radiation heat exchanger 2. Convective heat exchanger
3. Steam drum 4. Steam accumulator Courtesy of
Project Focus
EAF
Heat Exchangers
Thermal user ORC
EAF Heat Recovery: Waste Heat Boiler
Overview of Waste Heat Boiler LIFE+ logo
EAF
Heat Exchangers
Thermal user ORC
Fumes flow rate range 100,000 – 140,000 Nm3/h
Fumes inlet temperature ≈ 600°C
Fumes outlet temperature ≈ 220°C
Average steam flow rate 20 t/h
Average steam temperature 245°C
Average steam pressure 27 bar(a)
EAF Heat Recovery: Waste Heat Boiler
Agenda
Why the H-REII Demo
Technical aspects
the overall concept
the heat exchanger
the ORC
Francesco Campana – Turboden
Policy, regulatory aspects and dissemination
power
heat
Biomass
Waste-heat
Geothermal
Solar
Turboden designs and develops ORC turbines for the combined generation of heat and electric power from various sources, particularly suitable for distributed generation.
Organic Rankine Cycle turbogenerators
Sizes range: from 200 kW to 15 MW on a single turbine*
* Larger systems can be obtained trough modular design
Heat recovery through Turboden ORC
heat
Project Focus
ORC thermodynamics
The turbogenerator uses the heat carrier (e.g. hot temperature thermal oil) to pre-heat and
vaporize a suitable organic working fluid in the evaporator (834). The organic fluid vapor
powers the turbine (45), which is directly coupled to the electric generator through an elastic
coupling. The exhaust vapor flows through the regenerator (59) where it heats the organic
liquid (28). The vapor is then condensed in the condenser (cooled by the water flow or other)
(961). The organic fluid liquid is finally pumped (12) to the regenerator and then to the
evaporator, thus completing the sequence of operations in the closed-loop circuit.
Turbine
Generator
Pre-heater
Cooling medium
Condenser
Evaporator
Pump
Heat carrier
Electric energy
Tem
pe
ratu
re
Entropy
ORC compared to steam
Steam Rankine Cycle
Tem
per
atu
re
Entropy
Tem
per
atu
re
Entropy
Organic Rankine Cycle (ORC)
• High enthalpy drop • Superheating needed • Risk of blade erosion
• Small enthalpy drop • No need to superheat • No risk of blade erosion
Thermodynamic features and
consequences
• Water treatment required • Specialized personnel needed • High pressures and temperatures
• Non oxidizing working fluid • Minimum personnel and O&M(1)
• Automatic/self regulation(2)
Operation and maintenance costs
• Convenient for plants > 10 MW • Low flexibility • Lower performances at partial load
• High flexibility and good performances at partial load
• Well proven in industrial heat recovery
Other features
(1) Standard maintenance: 2-3 days per year (2) Fast start-stop procedure (ca. 20 min), partial load operation (down to 10% of nominal load)
EAF
Heat Exchangers
Thermal user ORC
Design point hot source mass flow 20 t/h saturated steam
Inlet temperature to ORC range 228÷245°C
Design inlet pressure to ORC 27 bar(a)
Design inlet thermal power to the ORC 13,517 kWth
Condensate outlet temperature from ORC 100°C
Cooling water temperatures (in/out ORC) 26/44°C
Thermal power to the cooling water 10,640 kWth
Gross electric power output guaranteed 2,680 kWe
Net electric power output 2,560 kWe
H-REII Demo: ORC power unit
31
EAF
Heat Exchangers
Thermal user ORC
Turboden unit installation phase
H-REII Demo: ORC power unit
Project timeline
Sep. 2014
H-REII Demo
conclusion
Jan. 2012:
H-REII Demo
Kick off
2012
Feb. – May 2013:
Components
delivered at ESF
waiting for EAF
annual
maintenance
shutdown
2012:
Components design,
manufacturing and
assembly
2013
Aug. 2013:
- heat
exchanger
installed
- ORC cold test
2014
Dec. 18, 2013
ORC first parallel
Dec. 19, 2013
nominal power
(2.6 MW) achieved
Mar. 2014:
Test on site
completed
Jun. – Sep. 2014:
Analysis of
performance data
collection
Performance Analysis
0
500
1.000
1.500
2.000
2.500
3.000
August 5, 2014 - Gross ORC Power output [kW]
Example of 12 hours operating at nominal load
Performance Analysis
0
10
20
30
40
50
60
70
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
August 2014 - ORC daily energy output [MWh]
Agenda
Why the H-REII Demo
Technical aspects
the overall concept
the heat exchanger
the ORC
Policy, regulatory aspects and dissemination
Daniele Forni – FIRE
Regulatory framework
A paper collecting incentive schemes and legislations across several EU Member States has been released. It provides an analysis of policies or preparative studies to support electricity generation from waste heat recovery. In particular data were collected regarding: • Belgium (Wallon Region) • France • Germany • Italy • Norway • Poland • Spain • Sweden • Netherlands • United Kingdom
And heat mapping georeferenced tools in Germany, Netherlands and UK.
Waste heat recovery potential in EU with ORC technology
Deliverable 07a: Contribution to the EU Energy Efficiency Action Plan
Process
Heat source T [°C]
PsORC [kW/t]
Plants
ORC
power [MW]
Flat Glass 500 2.33 58 79
Clinker Prod.
350 1.01 241 574
EAF 250 27.8 190 438
Rolling mills
400 6.87 209 310
GCS 30% 500 1 155
Total 2 556
ORC potential in EU Energy Intensive Industries
Sectors
Energy recovery [GWh/yr]
Emission avoided [103t CO2/yr]
5000h 8000h 5000h 8000h
Flat Glass 393 628 140 225
Cement 2 870 4 592 1 213 1 940
Steel 3 740 5 984 1 351 2 162
GCS 5 775 9 240 2 062 3 299
EU 27 12 778 20 444 4 766 7 626
Energy generated from WHR and CO2 emissions saving in EU27 industries
Annual energy recovery in EU27 industries
2.5 GW ORC potential in EII
20 TWh of electric energy
7.5 million tonnes CO2 emissions avoided
Published on October 25, 2012, entered into force on December 4, 2012 Transposed by Member States in summer 2014
Article Article content
Art 7 Energy efficiency obligation
schemes
Energy savings must be equal to 1.5% per year in the period 2014-2020 Financial schemes and instruments or fiscal incentives
Art 8 Energy audits and energy
management systems
Obligation of energy audit every 4 years for non-SMEs
Art 14 Promotion of efficiency in
heating and cooling
Assessment of the potential for the application of high-efficiency cogeneration and efficient district heating and cooling by December 31, 2015 Cost-benefit analysis for the refurbishment of plants > 20 MW of thermal input
Art 15 Energy transformation,
transmission and distribution
Assessment of energy efficiency potential of MS gas and electricity infrastructures MS shall ensure the removal of incentives and distribution tariffs detrimental to the overall efficiency of the generation, transmission, distribution and supply of electricity
Art. 20 Energy Efficiency National
Fund
MS may set up Energy Efficiency National Fund
Waste Heat Recovery has a relevant role in the EED and there are several provisions of interest for waste heat to energy systems
EU Energy Efficiency Directive (2012/27/EU)
Deliverable 07a: Contribution to the EU Energy Efficiency Action Plan
Relevant studies developed Studies Expected benefits from WHR through ORC technology
November 2012
Waste heat to energy to increase industrial competitiveness
AGICI - International Observatory for Renewables June 2013
Industrial policy instrument for relaunching the Italian industry
Smart Energy Project October 2013
1.7 billion € in 17 years the country system net benefit with 50% penetration on potential waste heat recovery in E.I.I. in Italy Industrial policy – competitiveness, sustainability, job creation
Sector Marginality variation
Chemical +2%
Products for building +12%
Steel +5%
Glass +11%
Deliverable 07a: Contribution to the EU Energy Efficiency Action Plan
Estimated potential for heat to energy recovery from UK industries: 1 TWh/yr
Relevance of H-REII project results in the ADEME analysis on existing policies in WHR at global level
Deliverable 07b: Contribution to the National Energy Efficiency Action Plan
Studies in France and UK
The Energy Efficiency Industrial Platform (EEIP)
• EEIP is a platform for Business and Policy in Europe, it facilitates dialogue within industry and between industry and policy • Strong involvement of H-REII DEMO in the EEIP work on industrial
heat recovery and financing of energy efficiency
www.ee-ip.org
Dissemination Activity
more than 13,000 website visits 100 events attended articles and papers Layman Report
www.hreii.eu/demo
ECOS 2014
Final Event - Webinar October 6, 2014
Marco Baresi – [email protected]
Marco Taesi – [email protected]
Simone Castrini – [email protected]
Francesco Campana – [email protected]
Daniele Forni – [email protected]
Waste Heat Recovery In Energy Intensive Industries
2012-2014 Project Results