corycos corycos · 2020. 10. 17. · corycos group - 140 kw orc clean cycle system 1 140 kw orc...

1Corycos Group - 140 kW Orc Clean Cycle System

.

140 kW ORCCLEAN CYCLE SYSTEM

CERTIFICATIONS

GROUPCORYCORY

CERTIFICATIONS

+1 650 704-2022+90 507 250-5258Call Us:www.corycos.com

www.corycos.com

CORYCOSCORYCORYCORYCORYCORY

2990 Redhill Avenue Costa Mesa California 92626 U.S.A.Akasya Acıbadem Lake Tower No:113 Üsküdar-ISTANBUL

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cory

cos

2 Corycos Group - 140 kW Orc Clean Cycle System

GLOBAL LEADER IN LOW TEMP ORC TECHNOLOGY!

1 MILLION OPERATING HOURSACROSS A GLOBAL FLEET


a. Technical Specifi cation Sheet

b. Key components of the Clean Cycle Solution

c. Process fl ow diagrams

d. Performance & recommendations

e. Dimensions and weights - air cooled

1- APPLICATIONS 04

2- KEY FEATURES 06

3- CLEAN CYCLE CONTAINERIZED SOLUTION 08

4- REFERENCE INSTALLATIONS 14

5- ABOUT CETY 22

6- CORYCOS GROUP & CETY 23

TABLE OF CONTENT


1- APPLICATIONS

Biomass & Wood Industry

Metals Manufacturing Cement & Glass

Landfi ll Gas to Energy Glass Manufacturing


Petrochemical Industry

Heavy Industry


Effi cient:Transforms 1 MW thermal wasteheat into 140 kW electricity

Safe:No fi re risk! No use of fl ammabelchemicals! Only Hot Water &RF245a

Minimal Maintenance: The turbine generator is onmagnetic bearings, so there’s nooil, lubricants, overhauls, ormanned operation required.

Re-deployable:We call it ‘heat source agnostic’...the Clean Cycle can run on - andeven be moved to - just about anyheat source of suffi cient temperature and fl ow rate.

Plug and Play:The Clean Cycle solution arriveswith generator, controls, powerelectronics, and software all built-inand ready to be paired to aheat source.

Over 100 units operatingworldwide

Americas & Europe

Proven

Generates electricity from

155°C HotWater

Low Temp

Standardized 140 kW Units

- easy to install

Modular

Automatically adjust to

changing heat input

Flexible

Over 100 units operatingworldwide

Americas & Europe

Proven

Generates electricity from

155°C HotWater

Low Temp

Standardized 140 kW Units

- easy to install

Modular

Automatically adjust to

changing heat input

Flexible

One Clean Cycle displaces 1,000 barrels of oil per year from diesel engine

consumption

One Clean Cycle Generates an extra1000 MWh/Year, enough to power

100 EU households

2- KEY FEATURES


Diesel Engie

Landfill Engine

Industry

Biomass Boiler

Cooling Tower

Making a diesel engine installation more fuel effi cient

INDONESIA - A Clean Cycle solution generates power from the waste heat of a 1.4MW containerized diesel engine, operating continuously.

* Increases engine fuel effi ciency by ~7%

* Saves ~ 175,000 liters of fuel per year

* Jacket water and exhaust heat are used as inputs for the Clean Cycle

Increasing power generation from a landfi ll gas plant

UNITED KINGDOM - A Clean Cycle solution generates power from the exhaust heat of two 1MW biogas engines.

* The Clean Cycle provides additional power that may be sold to the grid

* Has accumulated >10,000 operating hours and demonstrated 95% uptime

* Exhaust gas heat exchangers were installed on both engines to capture the heat

Generating power on-site from cement process heat

UNITED KINGDOM - 4 containerized Clean Cycle units use the waste heat from a biomass fi red lime kiln at a cement manufacturing facility.

* A single heat capture module delivers heat to the four Clean Cycle units

* Decreases customer electrical demand by 25%

* Reduces equivalent CO2 use by 1,600 tons per year

Creating electricity from biomass boiler heat

ITALY - At a pruning and composting plant, 2 Clean Cycle units convert heat from a biomass boiler, fueled by pruning clippings into electricity.

* Electricity is sold to the grid for a fi xed feed-in-tariff

* Units have been in operation since December, 2010

* 1,942kWth of heat from the boiler supplies the two Clean Cycle generators


a- Technical Specifi cation SheetDescription: The Clean Cycle has been designed with fl exibility in mind so that a wide variety of heat sources can be tapped to generate electricity. Regardless of the heat source, if it can create hot water or steam at suffi cient temperatures - typically through a heat exchanger - the Clean Cycle can generate electricity from it. The water or steam directed to the Clean Cycle is a closed loop, so no water consumption takes place. Similarly, the process by which the Clean Cycle generates electricity - called the Organic Rankine Cycle - requires no fuel, produces no emissions, and is closed loop.

Turnkey packageComplete assembly requires only heat input, interconnection, and minor control integration to begin producing electricity.

Seamless grid integrationElectricity produced by the generator is conditioned with power electronics to match 50 or 60 hz at a power factor of 1 automatically.

Automatically controlled & remotely monitoredThe unit adjusts to the heat provided to it, including automatic cut-in, load following, maximizing output, and automatic cut-out.

Low maintenanceCore generating equipment has no gearbox, no oils, no lubricants, no external rotating seals, and does not require manned operation; maintenance is typically performaned by existing on-site personnel.

Redeployable to other heat sourcesThe same package can be applied to reciprocating engine heat as well as biomass boiler heat or process heat.

FEATURES SPECIFICATIONS

Rating 140 kW gross electricalOutput 50 or 60hz, 3 phase 400-480VPower factor 1. Built-in power electronicsEmissions ZeroRefrigerant

Turbine

Generator

Cycle temperatures

Cycle pressures

Heat exchangers

R245fa, benign, non-fl ammable

Single stage radial

Rare earth magnetic bearing

25-144°C, 77-291° F

up to 25 bar

Brazed plate, on skidHeat delivery

Cooling

Pressurized water or steam

Air cooled radiator standard

Water cooled options also

availableSound 85 decibels at 1 meter; about

equal to a vacuum cleanerControls

Operation

Monitoring

Shipping

Allen Bradley controller

Unmanned operation

Remotely monitored

ISO 20ft container, redeployable

CERTIFICATIONSThe Clean Cycle meets strict international manufacturing standards.

3- CLEAN CYCLE CONTAINERIZED SOLUTION


Deliver heat and the Clean Cycle will do the rest

The Clean Cycle containerized solution has been meticulously engineered to reliable produce power from a variety of different heat sources. The major components, listed below, are assembled to create an automated machine to generate electricity from nothing other than a hot water or steam loop.

b- Key Components of The Clean Cycle Solution

Integrated Power Module (IPM)The IPM is mounted on the Clean Cycle skid and is a fully enclosed, hermetically sealed module that includes an integrated turbine generator that sits on magnetic bearings. The turbine rotor vibration is dampened by controlling the magnetic fi eld using a Magnetic Bearing Controller as it spins at 27,500 RPM. The turbine generator is self cooled, and there is no oil, lubricants, or gearbox required.

Clean Cycle GeneratorThe Clean Cycle is the heart of the containerized solution. The skid, pictured left, includes two brazed plate heat exchangers to transfer the heat from the water or steam to the refrigerant loop. From the heat exchangers, the refrigerant spins the turbine generator enclosed within the Integrated Power Module (IPM). The electricity is conditioned by on-board power electronics before being sent to the grid. The whole process is controlled by a central Controller & PLC.

ContainerThe Clean Cycle arrives mounted in the 20ft ISO shipping container that it arrives in. The team has modifi ed the container to have access doors, cut-outs for all necessary pipework to the heat source and condenser. It also has optional coating and salt screen with pressurization fan to prevent corrosion.

CondenserThe standard air condenser uses fans to cool the vapor refrigerant to a liquid after it leaves the IPM. The condenser ships separately with a mounting kit so it can be placed on top of the containerized solution. An epoxy coating is optional for installations near salt water to prevent corrosion. If cooling water is available on site, an optional water cooled heat exchanger mounted inside the container can be used in place of the air condenser.

• Included on the Clean Cycle skid• Self cooled... no oils or lubricants• No scheduled maintenance• Turbine speed... 27500 RPM• Radial, single stage turbine

• Includes... Turbine, generator, PLC, power electronics

• Dimensions... 3.8m x 1.2m x 2.1m• Weight... 3863 kg• Pressure rating... 25 bar• Temperature... 144°C

• Pre-cut doors & pipe access• Clean Cycle arrives mounted inside• Standard ISO shipping container• Dimensions... 6m x 2.4m x 2.6m• Weight... 3636 kg

• Dimensions... 9.3m x 2.6m x 2.7m• Weight... 5113 kg• Included... mounting kit & connection piping

Air cooled condenser (standard)

• Connects directly to Clean CycleWater cooled condenser (optional)


c- Process Flow Diagrams

The process by which the Clean Cycle generates electricity is called the Organic Rankine Cycle. In this closed loop process, a liquid refrigerant (shown in purple below) is pressurized and exposed to heat, causing it to vaporize. The pressurized vapor expands across an integrated turbine generator, causing it to spin and generate electricity. After the vapor exits the turbine, it is condensed to a liquid and pumped back to the heat source so the process can begin again. The heat is delivered to the Clean Cycle from a heat source in steam or pressurized water loop (shown in blue below).

Air cooled condensingRows of fans blow air across coils of refrigerant to condense it from liquid to vapor. The condenser ships separately and is mounted on top of the Clean Cycle container.

Water cooled condensing

If fresh water is available for use near the installation, the Clean Cycle can be confi gured with a condensingheat exchanger packaged inside the container. Water can be pumped directly into the heat exchanger tocondense the refrigerant.

Steam or hot water loop to deliver heatTo deliver heat from the heat source to the Clean Cycle, steam or pressurized hot water can be used. In bothcases, the heat is delivered in 3 inch pipes. In both cases, the Clean Cycle can automatically optimize thequantity of heat given to it with the 3 way valve pictured, and will start up, stop, and adjust according to theheat provided from the heat source. It is recommended that Temperature (T), Pressure (P), Water Level (L)and Flow (F) be measured in the water or steam loop to be able to make adjustments to meet the heat input.


Capturing and transferring the heat

The most common way to extract the heat energy from an exhaust stream is to use an exhaust gas heat exchanger, similar to the one pictured on the left. In this case, water is piped through the exhaust gas heat exchanger (pictured left), which transfers the exhaust heat to the water loop.

Protecting the heat source

Exhaust gas heat exchangers should be selected to extract the appropriate available amount of heat from the heat source, and ensure the protection of the heat source. This includes a bypass with diverting dampers, and sizing the heat exchanger so that it is within any backpressure limits that the heat source may have.

Quantifying the heat available

The usable heat in a medium can be calculated with a heat equation andcan often be found on equipment specifi cation sheets. The key pieces ofinformation to understand quantity of heat are: 1) the medium of the heatsource, 2) the mass fl ow rate, 3) the temperature.

UTILIZING EXHAUST HEAT

d- Performance & Recommendations

Clean Cycle units effi ciently operate on a variety of heat input conditions including partial and fl uctuating load. Units can be placed in parallel where suffi cient heat is available for more than one Clean Cycle generator. This enables signifi cant fl exibility while maintaining reliability and consistency across the different units in the fi eld.

One Clean Cycle operates at full electrical output with 980 kWth (3.3MBTU) supplied to it. The chart on the next page shows how with more heat available, more Clean Cycle units are used, and more electricity is generated.

One Clean Cycle unit running at full output will produce 140 kW of electricity at the generator and result 125kW exportable power from the Clean Cycle skid, after subtracting for auxilary power consumption. This is the net exportable power from the container for the water condensing version. For air condensing, up to 5 kW will be consumed by the air blast condenser depending on weather conditions.


Chart assumes 155°C pressurized water at 5.5 kg/s is delivered to the Clean Cycle unit(s) with ambient temperature of 25°C

Assumes water density @ 150C of 912kg/m3 and water Cp of 4.3kj/kg-k, and 25C ambient temperature

DESIGN CONSIDERATIONS

Ambient temperaturesIf the Clean Cycle is using an air condenser, the net power output from the unit will vary slightly depending on the ambient air temperature. In cooler conditions, net output may increase, and in warm ambient conditions, net output may decrease. This is due to the internal cycle that the equipment operates under and the effect is shown in the chart on the right.

Peaking and variable heat loadsThe Clean Cycle unit adjusts to variations in the quantity of heat supplied to it automatically. However, it is important to size the equipment for the heat condition that makes the most sense both technically and economically. For this reason, when performaning analysis it is recommended to look at heat source historical run data.

Flexible heat delivery confi gurationsWater or steam loops can be confi gured in a number of different ways to deliver heat to one or multiple Clean Cycle units. Below are a few examples of different confi gurations, and the Clean Cycle scope remains the same in each.

1 to 1One heat source to

one ORC...simple

2 to 1The heat from two sourcescan be combined in a single

water loop for one ORC

1 to 2+One heat source can feedmultiple ORC’s using water

loops in parallel

2+ to 2+Mutliple heat sources, (e.g.engines) can run multipleORC’s to maximize output


e- Dimensions and Weights - Air Cooled

DIMENSIONS

CONNECTIONS

PipeworkItem Type DescriptionHot Water Inlet 3” 300#ANSI From heat sourceHot Water Outlet 3” 300#ANSI To heat source

ElectricalItem Type DescriptionElectrical Connection GND 2/OAWG 4-Conductor To grid interconnection

1/0AWG Stranded To site or new grounding point

ControlsItem Type DescriptionInternet Wifi / Ethernet Clean Cycle load, demand, status

A multitude of variables and data can be viewed via the wifi / ethernet connectionThe Clean Cycle does not require other external control logic or inputs to operate

Civil work and logisticsThe Clean Cycle container arrives pre-assembled and is 8,600 kg unfi lled. Approximately 590 kg of R245fa refrigerant should be fi lled once on-site and ready to operate in accordance with the pre-commissioning checklist.

The site for the Clean Cycle container should be poured concrete or tamped gravel that is suitable for the weights and dimensions listed and secured. A crane is recommended for placing the unit.

Cooling with airThe air blast condenser arrives in a separate shipment and is to be mounted on top of the Clean Cycle container. The Clean Cycle container shipment will include the appropriate mounting kit and associated piping and control connections to connect the two.


SINCE 2009 GREATER THAN 1 MILLION OPERATING

HOUSE ACROSS A GLOBAL FLEETMORE THAN 100

UNITS INSTALLED

4- REFERENCE INSTALLATIONS


ITALY - MDF / PLYWOOD MANUFACTURING PLANT - 140 kW ORC SYSTEMIn Villanterio, Italy, a single unit generates electricity at a MDF/Plywood Manufacturing Plant from the heat of the biomass boiler. Wood and sawdust from the manufacturing operations feed the biomass boiler which is used the generate steam and hot oil for the plant. Besides generating power, Clean Cycle ORC Unit is used to balance temperature fl uctuations of the biomass boiler.


UNITED KINGDOM - CEMENT KILN - 480 kW ORC SYSTEMFour Containerized Units operate on a single heat source at a biomass fired lime-cement kiln in the United Kingdom. Four Units generate enough electricity to reduce electrical demand on-site by approximately 25%.

UNITED KINGDOM - LANDFILL GAS TO ENERGY (LFG) - 140 kW ORC SYSTEMIn the United Kingdom, landfill biogas engine supplies heat to operate a single Clean Cycle Unit. Exhaust from 2x1MW engines are captured and delivered to the containerized Clean Cycle Unit. This Unit has been running for 38,000 operating hours.


ITALY - DOOR MANUFACTURING PLANT - 280 kW ORC SYSTEMIn Pordenone, Italy, two Units generate electricity at I.C.M.’s Door Manufacturing Plant. Excess wood and sawdust from the door manufacturing operations feed the biomass boiler that produces heat for the building as well as the Clean Cycle ORC Units.

NEW YORK, USA. 1540 BROADTWAY TOWER COGEN -140 kW ORC SYSTEMThe 1540 building on Broadway installed a 1560 Kilowatt CHP Cogen system. The system is designed to provide continuous power for the building. The CHP waste heat will be utilized in the warmer months by using it to create an additional 140 kW of capacity using CETY HRS ORC Generator. This project has a tremendously positive impact on 1540 Broadway energy profile, and is exemplary of what can be achieved with high rise real estate assets.


FRANCE - LANDFILL GAS TO ENERGY (LFG) - 140 kW ORC SYSTEMIn France, a single unit is connected to the exhaust and jacket water of a biogas engine that operates continuously on landfill biogas. The ORC system generates additional electricity while improving biogas engine’s operating efficiency by reducing radiator’s cooling load.

INDONESIA -1.4 MW DIESEL GENERATOR - 140 ORC SYSTEMA single unit generates power from the waste heat of a diesel generator operating 24/7. Exhaust heat and jacket water heat are delivered to the ORC system in two separate hot water loops. Use of jacket water signifi cantly reduces electricity consumption by the generator’s internal radiator.


MARSHALL ISLANDS - BASELOAD DIESEL GENERATORS - 280 kW ORC SYSTEMTwo Clean Cycle™ heat-to-power generators installed in Majuro, Marshall Islands for the Marshall Electric Company (MEC) to help MEC offset engine fuel use and reduce CO2 emissions. HRS ORC technology empowers Island Nations’ utilities to achieve their energy sustainability and climate change goals.

ROMANIA - PETROLEUM REFINERY - 140 kW ORC SYSTEMIn Romania, a single Unit operates at a petrochemical refinery. Large boilers heat up a steam loop that is used for oil and gas processing. As part of the process, low temperature boiler exhaust was vented into the atmosphere until a unit was installed to utilize the low temperature heat and convert it into electricity.


NASHVILLE, TENNESSEE, USA - WASTE GASIFICATION PLANT - 420 kW ORC SYSTEMThe waste-to-energy downdraft gasifi cation plant built by Aries Clean Energy in Nashville,TN installed three Clean Cycle™ HRS ORC systems to produce 420 kWs of electricity from heat captured through the gasifi cation of approximately 64 tons of waste daily. The plant utilizes scrap tires, commercial wood waste, and biosolids from the adjacent wastewater treatment plant for feedstock.

USA - INDUSTRIAL WASTE BIOMASS PLANT - 140 kW ORC SYSTEMThe biomass plant utilized wasted heat from the exhaust stream to produce 140kW electricity with no additional fuel. CETY’s Organic Rankine Cycle Generator Clean Cycle IITM captures heat from the generators to produce substantial amounts of electricity.


ARNOLD MAERSK SHIP - 125 kW MARINE ORC SYSTEM


Clean Energy Technologies, Inc. (CETY) is a California-based energy technologies company publicly traded in the USA - OTC Stock Exchange. CETY designs, builds, and markets clean energy products and solutions focused on energy effi ciency and environmental sustainability technologies.

The Company’s principal product is the Clean Cycle II Organic Rankine Cycle (ORC) heat recovery generator acquired from General Electric. Our Clean Cycle II™ ORC heat recovery generator uses our patented magnetic bearing turbine technology to capture wasted heat from industrial manufacturing, waste processing and power generation facilities and converts it into electricity.

CETY’s Clean Cycle II ORC heat recovery generator is distinguished from its competitors by its magnetic bearing turbine technology offering lower maintenance and higher effi ciency. CETY has more than 1,000,000 fl eet operating hours and 8 years of history in the fi eld.

5- ABOUT CETY


DISTRIBUTOR OF TURKEYR&D AND MANUFACTURING PARTNER

USA OTC STOCK EXCHANGEPress Release (OTC:CETY)

Clean Energy Technologies Signs with Corycos Group to Market and Sell Products in Turkey, Closes First Sale December 04, 2018Costa Mesa, California, (December 4, 2018) Clean Energy Technologies, Inc. (OTC:CETY), a rapidly growing designer and producer of energy effi cient & environmentally sustainable products with its patented magnetic turbine heat recovery generator, announced today that it has entered into an agreement (through its wholly owned subsidiary, Clean Energy HRS, LLC) with Corycos Group an international Solar, Oil and Gas Energy company headquartered in Turkey to promote and sell its products in that country.

The agreement calls for Corycos to implement a business development plan to market and solicit orders for CETY products. Corycos has included CETY’s Clean Cycle II Organic Rankine Cycle (ORC) heat recovery generator in its product offerings to its clients in the Biogas industry as an important factor in improving effi ciencies in new and existing facilities.

This agreement and Corycos’ impressive reputation support CETY’s stated goals in both volume of sales and geographic expansion, as well as providing further evidence that this technology is an important element to improve the effi ciencies of, and produce added revenue from, existing facilities that produce waste heat, which is common among Corycos clients. This agreement has already resulted in the fi rst six-fi gure sale.

Ahmet Yigit Kazanc and Hakan Dogan, Co-Founders of Corycos Group added: “Waste to Energy represents the future of human civilization. It is not just an advancement in energy technology, it is a change of mindset and the future way of doing business. Strict energy effi ciency criteria and forward thinking, innovative and practical energy policies of the Republic of Turkey sets an example to rest of the world in terms of reducing GHG emissions and transforming heavy industry into state of the art modern, facilities.

Currently, many landfi ll biogas-fueled power plants biomass-powered industrial facilities exist in the Republic of Turkey. As a nation bridging the East and the West, CETY’s Turkish installations will serve as showcases to the rest of the world. Benefi ts of environmentally friendly small, scalable waste to energy solutions are undeniable and the exponential growth of that industry is impossible to ignore.

Corycos is pleased to work with Clean Energy Technologies and introduce their product line into our extensive client base. CETY’s technology is a perfect fi t for our business and we are excited about where this agreement will lead.”

6- CORYCOS GROUP & CETY

CERTIFICATIONS

UNITED STATES OF AMERICA2990 REDHILL AVENUE,COSTA MESA, CALIFORNIA 92626

AHMET YIGIT KAZANCGsm: +1 650 704 - 2022 E-mail: [email protected]

REPUBLIC OF TURKEYAKASYA ACIBADEMLAKE TOWERNO: 113USKUDAR, ISTANBUL

HAKAN DOGANGsm: +90 507 250 - 5258E-mail: [email protected]

General Electric Company

Clean EnergyTechnologies, Inc.

www.corycos.com

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