experience and progress with orc turbogenerators in

Carlo Minini

10th Bioenergy Business Breakfast Doc.: 14-4-356-rev.0

Date: 23/05/2014

Experience and progress with ORC turbogenerators in Australia

including the new 200-300 kWe units

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About Us

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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 Mario Gaia, Professor of Energy at the Politecnico di Milano, and today 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: to 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 UTC Corp., a worldwide leader in development, production and service for aero engines, aerospace drive systems and power generation gas turbines, to develop ORC solutions from renewable sources and waste heat worldwide. In 2013 UTC exits the power market forming strategic alliance with Mitsubishi Heavy Industries. In 2013 Mitsubishi Heavy Industries acquires from UTC Pratt & Whitney Power Systems (now PW Power Systems, Inc.) and the affiliate Turboden. Today Turboden s.r.l. and PW Power Systems, Inc. are MHI group companies to provide a wider range of products and services for thermal power generation systems. In 2013 Turboden’s Quality Management System gets certified to ISO 9001:2008.

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1984 – 40 kWe ORC turbo-generator for a solar plant in Australia

1987 – 3 kWe ORC turbo- generator for a biomass plant in Italy

2008 – 3 MWe ORC turbo-generator for heat recovery on a waste incinerator in Belgium

1988 – 200 kWe ORC geothermal plant in Zambia

2009 – First 100 plants and first installed 100 MWe

2010 – First plant overseas

2014 – Over 250 ORC plants in the world and back to Australia

Over 30 Years of Experience

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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

• 24/7 remote assistance available

• 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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heat

standard units from 200 kW to 15 MW

customized solutions up to 20+ MW

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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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The Thermodynamic Principle: The 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 Plants – Performance

• Gross electric efficiency: up to 24% and more

• Overall energy efficiency: 98%

100%

18 to 24%

2%

80 to 74%

Thermal power from thermal oil (or other heat carrier)

Thermal power to heat users

Gross electric power

Thermal losses (insulation and generator losses)

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ORC Plant in a Process of Cogeneration from Biomass

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Why High Molecular Mass Working Fluid Instead of Water?

Water • Small, fast moving molecules • Metal parts and blade erosion • Multistage turbine and high mechanical

stress

Organic Fluid • Very large flow rate • Larger diameter turbine • No wear of blades and metal parts

WATER HIGH MOLECULAR MASS FLUID

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Advantages of Turboden ORC Turbogenerators

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Technical advantages High cycle efficiency Very high turbine efficiency (up to 90%) 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 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 High Availability (confirmed by more than 4 million hours of operation)

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Turboden ORC Plants in the World

> 200 biomass applications in 26 countries

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What we have done up to now*

* May 2014

281 Turboden ORC References in the World in 32 Countries

246 applications in biomass in 26 Countries

By applications: By sizes: - 108 District heating From 200 kWe to 3 MWe < 400 kWe 7

- 43 Sawmills and wood industry From 600 kWe to 6.5 MWe 0.4 – 1 MWe 115

- 3 MDF (Medium Density Fiber) From 1 MWe to 1.3 MWe 1 MWe power only (12HRS) 22

- 33 Pellet industry From 600 kWe to 2 MWe 1 - 2 MWe 82

- 5 Public buildings: CCHP (Combined Cooling Heating Power) From 600 kWe to 1.8 MWe 2 - 5 MWe 26

- 15 CHP In industrial processes (Agroindustry, Wood industry,..) From 200 kWe to 1.3 MWe > 5 MWe 11

- 24 Power Only 12 HRS: 1 MWe Pure Cycle 3

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Solid biomass CHP applications with ORC

some CHP applications size range

District heating 0.2 - 3 MWe

Sawmills - wood industry 0.6 - 13 MWe

MDF 1 - 1.3 MWe

Pellet industry 0.6 - 2 MWe

CCHP Public buildings / Industrial processes 0.2 - 1.8 MWe

Fuels • Wood biomass: sawdust, woodchips, bark, treated

wood • Other biomass: dried sewage sludge, green cuttings,

rice husks, oat husks, olive husks, vinasse and vine cuttings, etc.

• Waste material (municipal or industrial solid waste)

Heat Consumers • District Heating networks • Timber drying in sawmills • Sawdust drying in wood pellet factories • MDF/PB Producers • Air pre-heating in MDF industry • Refrigeration, trigeneration (chillers) • Greenhouses • Wine industry

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Reference Plant – ITC, Turkey

Location: Ankara (Turkey) Client: ITC-KA Enerji Uretim Sanayi Ve Ticaret A.S. Start-up: Q1 2014 Heat source: industrial waste gasification Source temperature: 315°C (thermal oil) Water temperature (in/out): 25-35°C Electric Power: 5.5 MWe

Net electrical efficiency: ∼25%

Project description: the high efficiency Turboden 55-HRS

unit exploits the heat from the combustion of the synthesis

gas generated from industrial waste.

The gas is burned in a boiler that heats up the thermal oil

that carries the 20 MWt input into the ORC module.

The cooling is done through wet cooling towers.

The client is installing a second 55-HRS unit and is looking at

a number of 110-HRS units (∼11 MWel each) to use with

municipal waste in the near future

Waste to Energy

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Reference Plant – MSG, WA

Location: Wagin (WA) Client: Morton Seed and Grain Start-up: Q1 2015 Heat source: oat husks Source temperature: 23 bar(a) saturated steam Water temperature (in/out): 27.5-38°C Electric Power: 600 KWe

Net electrical efficiency: 17%

Project description: The proposed facility will convert

between 6,000 and 10,000 tons of oat husk per year.

The Turboden 6 HR split unit will be fed with saturated steam

instead of the traditional thermal oil and will be used at part

load (60-80%) most of the time for a couple of years, taking

advantage of its ability to follow variable loads and retain high

part load efficiency (e.g. at 50% load, around 90% of the

nominal load efficiency).

The estimated project value of about AU$3.8 Million.

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New Turboden 2 and Turboden 3 Dual Mode

Layout: compact, containerised Dual Mode: Power only or CHP Heat carrier: thermal oil or saturated steam Inlet temperature: 200 to 310°C Water temperature (in/out): 35-55 to 75-95°C Gross Electric Power: 200 to 300 KWe

Gross electrical efficiency: 12.5 to 17.5%

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New Turboden 2 and Turboden 3 Dual Mode

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Plant type: heat recovery from pressurized water boiler in urban waste incinerator Customer: MIROM Location: Roeselare, Belgium In operation since: II quarter 2008 Availability: > 98% Heat source: hot water at 180°C (return at 140°C) Cooling source: water/air Total electric power: 3 MW

Net electric efficiency: 16.5% Non flammable working fluid: to meet customer’s requirement

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Reference Plant n.1 – Mirom, Belgium 1/2 Waste to Energy

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Reference Plant n.1 – Mirom, Belgium 2/2

Initial installation in operation since: 1976 Treatment capacity: 62.000 ton/year urban waste Boilers: 2x 8MWth

Use of heat: hot water at 180°C (return at 140°C) District heating since: 1986, 21 customers, 7.5 km ORC project started: 2006, in operation since 2008 in parallel to district heating use

Before After

Waste to Energy

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Pellet process and Turboden ORC integration

ORC Flexibility and Reliability

Pellet Manufacturing Process

The integration between the Turboden ORC and an existing or brand new Pellet manufacturing process gives the possibility to

diversify the business producing, at the same time, Pellet and Electrical Energy from

Renewable Sources (i.e. biomass)

Industrial process productivity needs

Biomass References

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**Assuming Turboden CHP and Belt dryer configuration

•Source: Bioenergy International May 2011, Prodesa Medioambiente – “Cogeneracción y producción de pellet”

Sample case:**

•ORC Unit: Turboden 10 CHP integrated in a Pellet plant

•Pellet production capacity = 4 tons/h

•Pellet production = 30,000 tons/y

•Biomass Consumption = 57,500 tons/y

•Boiler installed = 5.2 MWth

•Electrical power installed = 1 MWel

•Thermal power output = 4.1 MWth at 60/80°C

Dimensioning Parameters

ORC Size Pellet production capacity**

Turboden 10 CHP Split (4,100 kWth) 30,000 t/y*

Turboden 14 CHP Split (5,340 kWth) 42,000 t/y*

Turboden 22 CHP Split (9,598 kWth) 85,000 t/y

Turboden 30 CHP Split (13,636 kWth) 120,000 t/y

Biomass References

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Example of Pellet application

Mudau in Germany - MU

Context / Special Feature

A/ Pelletisation process - Max pellet production: 6t/h - Hot water to dry saw from 50% to 10% B/ Specificity: Application Pellet - Biomasse boiler: 6570 kWth - Cogénération withORC: 5,335kWth 1,187 kWe (brut); 1,124 kWe (net) - belt dryer supplier: Stela - Pelletisation system supplier: Salmatec

Model: T1100 Client: BIO-ENERGIE MUDAU GMBH & CO.KG Start up: June 2006 Location: Mudau - Germany Fuel: Wood chips Electric power: 1,187kWe Thermal Use: drying belt in pelletisation process Thermal power: 5,335kWth Water Temperature: 60-85 °C Boiler supplier: Kohlbach

Biomass References

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Combined Heat & Power (CHP) with Split system Standard Sizes and Typical Performances

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experience and progress with orc turbogenerators in

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