Geothermal – Wind – Biomass – Waste Heat

Istanbul, June 25, 2010

Presented By
Organic Rankine Cycle (ORC)
in Biomass application
Paolo Bertuzzi
Turboden General Manager – Finance & Commercial Area

2
Modular ORC Units for biomass applications

Heat Recovery Geothermal Solar Thermal Power

Biomass
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.

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 Advantages of ORC technology

Technical advantages Operational advantages / results

ciency (up to 85%) ØAutomatic and continuous operation
ØSimple start-stop procedures
ss of the turbine due to the low peripheral speed
ØNo operator attendance needed
ne allowing the direct drive of the electric generator without reduction gear
ØHigh efficiency at partial load and operation down to 10% of nominal po
no water treatment system due to absence of water
ØVery safe and quiet operation
ØLow maintenance
ss of the cycle due to much lower pressure requirements: planned maintenance once per year, no
than steam cycle
ØVery High Availability (e.g. Admont, AUT: operation since 1998, availabil
ØLong life – designed for 20+ years

Translate in user advantages

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Advantages of ORC technology

5
Modular ORC Units
Layout Turboden 10

Condenser Regenerator Electric generator

Pre-heater

Electric cubicles ORC turbine

Feed Pump Evaporator

6
Modular ORC units for biomass applications

Solutions

ØCHP UNITS
ØHRS - POWER ONLY UNITS
ØHYBRID SOLUTIONS

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ORC Plant in a Process of Cogeneration from Biomass (CHP)

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Why Distributed Biomass-Fueled CHP?
Ø sustainable & renewable: CO2
neutral and re-growing fuel
Ø
Ø local energy source: no
dependence on volatile global
fossil fuel markets
Ø
Ø local base-load electric power:
relief for congested
transmission lines
Ø
Ø impact on economy: uses a local
supply chain and keeps energy
revenues local
Ø
Graph source: “Der biologische geschlossene Kreislauf”
www.biomasseverband.it (April 2010) Ø clean technology: small plants -
easier permit



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
Biomass Energy: Centralized Electric Power

Graph source: Neil Øoptimized electric efficiency

Harrison: „Wood burns:
an urban myth?“
Ølow total energy efficiency (< 40%; no use of heat)
Presentation held at Øhigher biomass transport cost & transmission losses
„International Biomass
Conference“, Portland,
OR, 2009

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Biomass Energy: Distributed CHP

Graph source: Neil Øvery high total energy efficiency (CHP)

Harrison: „Wood burns: an
urban myth?“ Presentation Øhigher specific investment cost
held at „International Ølow biomass transport cost & transmission losses
Biomass Conference“,
Portland, OR, 2009

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ORC Plants – Perfomances

100 % 78%
Thermal
Thermal power to heat
power from users
thermal oil

20 %Gross electric power

Thermal losses (insulation

2 % and generator losses)

ØGross electric efficiency: nearly 20%

ØOverall energy efficiency: 98%

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Combined Heat & Power (CHP) without Split System

Combined Heat & Power (CHP) - Standard Sizes and typical performances
TURBODEN 4 TURBODEN 6 TURBODEN 7 TURBODEN 10 TURBODEN 14 TURBODEN 18 TURBODEN 22
CHP CHP CHP CHP CHP CHP CHP
INPUT - Thermal oil
Nominal temperature (in) °C 300 300 300 300 300 300 300
Nominal temperature (out) °C 240 240 240 240 240 240 240
Thermal power input kW 2300 3240 3815 5140 6715 9790 12020
OUTPUT - Hot water
Hot water temperature (in/out) °C 60/80 60/80 60/80 60/80 60/80 60/90 60/90
Thermal power to the cooling water circuit
kW 1854 2565 3038 4081 5313 7834 9601
PERFORMANCES
Gross active electric power kW 427 641 737 1016 1339 1863 2304
Gross electric efficiency 0,186 0,198 0,193 0,198 0,199 0,190 0,192
Captive power consumption kW 21 30 35 48 58 79 97
Net active electric power kW 406 611 702 968 1281 1784 2207
Net electric efficiency 0,177 0,189 0,184 0,188 0,191 0,182 0,184
asynchronous asynchronousasynchronous asynchronous asynchronous asynchronous asynchronous
Electrical generator triphase, L.V. triphase, L.V. triphase, L.V. triphase, L.V. triphase, L.V. triphase, L.V. triphase,
400V 400V 400V 400V 400V 660V L.V.660V
Plant size Single Skid Single Skid Single Skid Multiple Skid Multiple Skid Multiple Skid Multiple Skid
Biomass consumption* Kg/h 1106 1558 1834 2471 3228 4707 5779
*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.

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Combined Heat & Power (CHP) with Split System

Combined Heat &Power (CHP) withsplit - Standard Sizes andtypical performances *

TURBODEN 4 TURBODEN 6 TURBODEN 7 TURBODEN 10 TURBODEN 14 TURBODEN 18 TURBODEN 22
CHP CHP CHP CHP CHP CHP CHP
“split” “split” “split” “split” “split” “split” “split”
INPUT- Thermal oil
Nominal temperature "HT" loop (in/out) °C 310/250 310/250 310/250 310/250 310/250 312/252 312/252
Thermal power input "HT" loop kW 2100 2965 3485 4690 6130 8935 10975
Nominal temperature "LT" loop (in/out) °C 250/130 250/130 250/130 250/130 250/130 252/132 252/132
Thermal power input "LT" loop kW 200 275 330 450 585 855 1045
Overall thermal input kW 2300 3240 3815 5140 6715 9790 12020
OUTPUT- Hot water
Hot water temperature (in/out) °C 60/80 60/80 60/80 60/80 60/80 60/90 60/90
Thermal power to the cooling water circuit kW 1844 2600 3060 4100 5350 7850 9630
PERFORMANCES
Gross active electric power kW 424 617 727 1001 1317 1862 2282
Gross electric efficiency 0,184 0,19 0,191 0,194 0,196 0,19 0,189
Captive power consumption kW 24 30 38 51 62 87 107
Net active electric power kW 400 587 689 950 1255 1775 2175
Net electric efficiency 0,174 0,181 0,181 0,184 0,186 0,181 0,181
asynchronous asynchronous asynchronous asynchronous asynchronous asynchronous asynchronous
Electrical generator triphase, L.V. triphase, L.V. triphase, L.V. triphase, L.V. triphase, L.V. triphase, L.V. triphase, L.V.
400V 400V 400V 400V 400V 660V 660V

Plant size Single Skid Single Skid Single Skid Single Skid Multiple Skid Multiple Skid Multiple Skid
Biomass consumption** Kg/h 1005 1416 1667 2247 2935 4279 5254
* The Turboden split systemallows 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.

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Biomass – Fuels & Applications

FUELS
qWood biomass:
sawdust,
woodchips, APPLICATIONS
bark,
treated wood qTimber drying
in sawmills
Turboden standard unit
qOther biomass:
dried sewage sludge, qSaw dust drying
straw, in wood pellet factories CHP
green cuttings, for cogeneration and/or trigeneration
rice husk qAir pre-heating
in MDF industry Up to 20% efficiency
qWaste material •
q qDistrict Heating networks
qWaste recycling wood •
q qRefrigeration /
q air conditioning

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ORC Application in Sawmills
ELECTRIC
POWER

Thermal
BIOMASS oil
POWERED
BOILER
bark sawdust ORC

TRUNKS SELECTION BARKING PROCESSING

cold water

hot
water

PRODUCT PACKAGING DRYING

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Saw Mill ‘Mayr-Melnhof in Leoben (Austria)
Ø Biomass-fueled thermal oil boiler:
Ø 32,5 MW biomass input power - 28 MW thermal oil output
power
Ø Thermal oil temperature 300°C (572°F)


Ø 3 x Turboden 1,5 MWe units:

Ø el. capacity 4,5 MWe - annual electricity production: 36 GWh
Ø hot water capacity: 23 MWth - annual heat production
(hot water @ 95°C (203°F)): 192 GWh y 650 000 MMBtu


Ø Heat users:
Ø Lumber drying kilns
Ø Pellet plant (75 000 t/year)
Ø Office space heating


Ø Started up: April 2005



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CHP Applications: Wood Pellet Production with ORC

Thermal Electric power

BIOMASS oil
POWERED
BOILER
cold
ORC water

hot
water

TRUNKS BARKING WOOD CHIPS CHIPPING

DRYING

SELECTION

READY PELLETS
COOLING PELLET MAKING DEDUSTING
PRESS SELECTION REFINING
pellets

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Case study – Pellet application

Customer: Bio-Energie Mudau GmbH & Co. KG

Location: Mudau - Germany
Start up: October 2006
Model: T1100 CHP
Electric Power: 1100 kW
Thermal Power to the cooling water circuit: 5335 kW
Water Temperature (in/out): 60°- 85°C
Fuel: woodchip
Application: Pellet

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CHP – District Heating Networks

WITHOUT ORC BIOMASS BIOMASS POWERED BOILER

cold
water

hot
water
HEAT USER

Electric power

BIOMASS POWERED
WITH ORC BIOMASS
BOILER cold
Thermal water
ORC
oil
hot
water
HEAT USER

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Case study – District heating application

Customer: T.C.V.V.V. Spa

Location: Tirano (SO) Italy
Started up: June 2003
Model: T1100 CHP
Electric Power: 1.1 MW
Thermal Power to the cooling water circuit: 4.8 MW
Water Temperature (in/out): 60°- 80°C
Fuel: woodchip
Application: District heating network

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Biomass CHP District Heating in Vipiteno (Italy)
Ø District heating network length 45 km with 750 connections
Ø
Ø Regular winter heat demand: 12-14 MW
with peaks up to 22 MW thermal
Ø
Ø Baseload installations:
Ø Biomass thermal oil boiler (7 MW thermal)
Ø Turboden ORC unit:
Ø electric capacity: 1,2 MWe
Ø hot water capacity: 5,5 MW
Ø
Ø Additional peaking installations:
Ø 8,6 MW biomass water boiler
Ø 8 MW hot water storage
Ø
Ø Back-up boiler
Ø 9 MW fuel oil boiler
Ø

ØStarted up: January 2008

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The District Heating Model in Central Europe
Ø Small and medium-size communities (typically 2000-10000 inhabitants)
Ø Starting point: main heat users as community buildings, school/college,
hospital, large commercial & industrial users
Ø Small residential users can follow
Ø Modern hot water piping infrastructure has a life time of 40-50 years
Ø Strong regional policy support for sustainable development:
Ø Investment incentives depending on region
Ø Long-term feed-in rates for electricity from biomass
Ø Financial/Investment schemes:
Ø Local utilities
Ø Co-ops with farmers, forest owners & communities
Ø Local private long-term thinking investors

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Case study – Industrial process application

Customer: Parboriz Spa

Location: Mortara (PV) Italy
Started up: July 2008
Model: T600 CHP
Electric Power: 600 kW
Thermal Power to the cooling water circuit: 2.8 MW
Water Temperature (in/out): 60°- 80°C
Fuel: rice husk
Application: Industrial process (production of
parboiled rice)

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Case study – MDF application

Customer: MDF Hallein GmbH & Co KG

Location: Hallein Austria
Started up: Nov 2005
Model: T1500 CHP
Electric Power: 1500 kWe
Thermal Power to the cooling water circuit: 7100kWth
Water Temperature (in/out): 60°- 90°C
Fuel: waste biomass from the process
Application: Industrial process (production of MDF
panels)

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Modular ORC units for biomass applications

Solutions

ØCHP UNITS
ØHRS - POWER ONLY UNITS
ØHYBRID SOLUTIONS

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HRS – High electrical efficiency units
HRS for electricity generation and cogeneration from biomass

Gross performance of
the Turboden HRS
modules at various
condensation water
temperatures

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HRS – High electrical efficiency units

TURBODEN 12 and 24 HRS for BIOMASS application

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HRS – High electrical efficiency units

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Fuels & Applications

FUELS
qWood biomass:
sawdust,
woodchips,
bark,
treated wood APPLICATIONS
Turboden standard unit
qOther biomass: qGreenhouses
dried sewage sludge, q HRS
straw, qSwimming pool
(power only)
green cuttings, q
rice husk qThermal bath
q Up to 24% efficiency
qWaste material qNo thermal users
q
qWaste recycling wood
q
q

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Case study – HRS woodchips plant in southern Italy
Customer: Fiusis s.r.l
Location: Calimera (Lecce) - Italy
Start-up: 3rd quarter 2010
Model: Turboden 12 HRS
Electric Power: 999 kWe
Thermal Power to the cooling water circuit: 4500 kWth
Water Temperature (in/out): 25°- 35°C
Fuel: woodchips (mainly from olive trees)
Application: power production from woodchips

The Italian newspaper

Il Sole 24 Ore issued
an article on this plant

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Modular ORC units for biomass applications

Solutions

ØCHP UNITS
ØHRS - POWER ONLY UNITS
ØHYBRID SOLUTIONS

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Hybrid solar thermal power plant

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Solar thermal power technology

Parabolic trough system

Solar Millenium collectors

Solel collectors

ENEA collectors

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Solar thermal power technology

Poin focal solar power tower

Solar Two, California

PS 10, Seville

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Case Study – Hybrid Solar Thermal Power Plant

electric power
hot thermal oil
output

cold thermal oil

Fig.: Simplified configuration diagram of an ORC hybrid solar thermal power plant

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Case Study – Hybrid Solar Thermal Power Plant

Simulation Software:
day 1 day 2 day 3 day 4 day 5 day 6 day 7

power input in a one week time

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Case Study – Hybrid Solar Thermal Power Plant

Power output: 1 MWel

Fig.: Preliminary layout out of a hybrid solar thermal power plant using Turboden 12 HRS

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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)

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Analysis for Turkish market: Hypotheses

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.
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

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Analysis for Turkish market: Hypotheses
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 €
* 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

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Analysis for Turkish market: Hypotheses

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 €

* 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

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Turkish example: with feed in tariff (0.14 €/kWh)

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Turkish example: Incentive vs Biomass cost

Tariff currently under discussion*

Tariff

* Source: Platts Renewable Energies Report - Nov. 2009

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Turkish example: Incentive vs Biomass cost

Tariff currently under discussion*

Tariff

* Source: Platts Renewable Energies Report - Nov. 2009

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Please contact us!
 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

korkurtakin@transnationalvc.com

Alessandro Guercio
Sales Manager Biomass Department at Turboden

alessandro.guercio@turboden.it

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Thanks for your attention!