turboden-woodenergyinformationday1
TRANSCRIPT
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TURBODEN ORC UNITS:
A WELL PROVEN SOLUTION
FOR SMALL SCALE BIOMASS CHP PLANTS
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Wood Energy information dayWednesday 19 th November 2008
The Manor House Resort Hotel , Killadeas, Co. Fermanagh
Ilaria Peretti - [email protected]
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Organic Rankine Cycle (ORC) concept
ORC is a commercial technology for distributed
production of combined heat and power from various
energy sources.
Turboden T600-CHP
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Agenda
• Turboden Company Profile
• ORC unit in Biomass Cogeneration
• Technical Advantages/Results
• Sawmill plants application: viability
• Pellet plants application: key-study
• Conclusions
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Established in 1980 with the aim to design and manufacture
turbines and turn-key turbogenerator units based on the Organic
Rankine Cycle (ORC).
1984: 40 kWel ORC turbogenerator for
a solar application in Perth, Australia
1987: 3 kWel ORC turbogenerator biomass
CHP plant in Milan
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Company profile: the origin
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•Turboden designs and develops ORC turbogenerators well suited
for distributed energy generation with the following power
ranges:
•200 kW to 2 MW for standard size Turbogenerators
•up to 10 MW for customized products
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Company profile: today
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Map of TURBODEN ORC units 1/2
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Map of TURBODEN ORC units 2/2
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Pellet Plant
T2000-CHP-Split
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Company profile: Figures of a growing company
31/08/2008 Backlog: 59 M €
31/12/2007 Equity > 5 M €
•(*) estimated figures as of August 31st 2008
EMPLOYEES
PRODUCTION VOLUME (M€)
0,00
5,00
10,00
15,00
20,00
25,00
30,00
35,00
40,00
1998 2000 2002 2004 2006 2008 2010
0
10
20
30
40
50
60
70
80
90
1998 2000 2002 2004 2006 2008 2010
12/2000 12/2006 12/2007 12/2008
(*)
Employees 7 51 74 103
ProductionVolume (M €)
1,4 23,5 29,5 40
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Turboden’s new headquarters (shop and offices)
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ORC Plants in the cogeneration process
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Thermal
power from
thermal oil
100 %
19 %
Net electric power
2 % Thermal losses (insulation and
generator losses)
79 %
Thermal power
to heat users
Overall Thermal Efficiency: 98 %
Net Electrical Efficiency: 19%
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• High cycle efficiency
• Very high turbine efficiency (up
to 85 %)
• 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, due to
the absence of moisture in
the vapour nozzles
ORC technical advantages • Fully Automatic operation and
start - stop
• No operator attendance needed
• Quiet operation
• Very High Availability (e.g.
Admont – over 50,000 hours of
operation, availability > 98%)
• Partial load operation down to
10% of nominal power
• High partial load efficiency
• Low O&M requirements: 3-5
hours / week
• Long life
Operational results
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CHP – Fuels & Applications
• Fuels
• Wood biomass: sawdust,
woodchips, bark, treated wood.
• Other biomass (dried sewage
sludge, straw, green cuttings,
rice husk, etc.).
• Waste material.
• Heat Consumers
• Timber drying in sawmills.
• Saw dust drying in wood pellet
factories.
• Air pre-heating in MDF
industries.
• District heating networks.
• Refrigeration.
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Sawmill plants application: viability
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CHP plants with ORC units
coupled to drying chambers in sawmills
trunks selecting barking
dryingdryingpackaging product
processing
Biomass powered
boilerORC
thermal
oilelectric
power
hot
water
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CHP Applications: Sawmills
Some reference Plants
Sawmill Theurl - (Tyrol, Austria): T1100-CHP – 2004
Sawmill Schwaiger (Hengersberg, Germany): T1500-CHP – 2005
Sawmill Mayr-Melnhof (Leoben, Austria): 3*T1500-CHP – 2005
Holzwerke Gmach (Pösing, Germany): T1500-CHP – 2005
Holzwerk Weinzierl (Vilshofen-Alkofen, Germany): T1500-CHP – 2005
Sawmill Templin (Templin, Germany): T600-CHP – 2005
Sawmill Echtle (Nordrach, Germany): T800-CHP - 2006
Sawmills Ludwig Ziegler (Plössberg, Germany): T1500-CHP – 2006
Holzindustrie Pfeifer (Imst, Austria): T800-CHP – 2006
Sawmill Anteholz (Bromskirchen-Somplar, Germany): T1500-CHP - 2007
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PLANT TECHNICAL FEATURES PLANT CONFIGURATION
Combustion system Drying chamber CHP
Thermal oil boiler efficiency (including
Split system)- 90%
Hot water boiler efficiency (including
water economizer)90% -
Thermal oil boiler own consumption
[kWel/MWth]*- 25
Hot water boiler own consumption
[kWel/MWth]15 -
Drying chamber process Drying chamber CHP
Inlet wet product moisture 40% 40%
Outlet dry product moisture 15% 15%
Drying efficiency 50% 50%
Hot water temperature inlet drying
chamber (about) [ C]90 90
Technical assumptions:
Combustion system, Drying chamber process 1/2
* Referred to thermal oil power
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Technical assumptions:
Combustion system, Drying chamber process 2/2
• Starting from these assumptions we can obtain
a thermal energy requirement of 0.24 MWh/m3 dried wood
• Assuming a load factor of 6.500 full load operation hours per
year every standard size of the ORC unit can be linked to
a yearly dried wood production
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Technical characteristics and the related production
capacity (m3/year) for all ORC sizes
T200-CHP Split T500-CHP T600-CHP T800-CHP T1100-CHP Split T1500-CHP Split T2000-CHP Split
Thermal power
input from
thermal oil (kW)
1.340 3.240 3.910 5.140 6.715 9.790 12.020
Hot water
temperature out
from ORC ( C)
90 90 90 90 90 90 90
Thermal power
output to hot
water (kW)
1.108 2.637 3.191 4.148 5.426 7.920 9.700
ORC net electric
power (kWel)205 538 641 889 1.155 1.674 2.079
ORC net electric
efficiency 15,3% 16,6% 16,4% 17,3% 17,2% 17,1% 17,3%
Full load
operation hours
(hr/year)
6.500 6.500 6.500 6.500 6.500 6.500 6.500
Thermal energy
supplied to the
drying chambers
(MWh/year)
7.200 17.100 20.700 27.000 35.300 51.500 63.100
Dried
production
(m3/year)
30.000 71.400 86.400 112.300 147.000 215.000 263.000
ORC net electric efficiency = net electric power / thermal power input from thermal oil
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Discussion of main economic parameters and assumptions
ADDITIONAL INVESTMENT COSTS
CHP - Only drying chamber
Turboden ORC unit 1
Boiler 1,1
Civil work 0,5
Engineering 0,15
Overall (drying chamber excluded) 2,75
Assumed differential investment costs between a CHP plant and a heat only plant as
multiplier of ORC costs.
Cost for dying chambers = not considered (not relevant for the differential study)
275% of ORC cost + 100 k€ (grid connection): c.a. 2.800 k€ (T500) – 5.400 k€ (T2000)
Assumptions of this study: economic data and values 1/2
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• Electricity Value: 0,1 - 0,25 Euro/kWhel
• Biomass costs (assuming a calorific value of 2,5 kWh/kg) : 20 Euro/MWh (50 €/ton)
• Full load operation hours: 6500 hours/year
• Discount rate: 5%
Assumptions of this study:
Economic data and values 2/2
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Economic analysis results
Constant hot water feed Temperature = 90°C. Calorific value=2,5 kWh/kg
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Pellet plant application: key-study
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CHP PELLET plant:
Based on ORC unit coupled to BELT dryer
Thermal oil
biomass powered
boiler
ORC
thermal
oil
electric
power
UR < 13 %
trunks chipping
wood
chips
selection/
sorting
suitable granulometry;
UR around 40 %
pellet making
press
dedusting/
selection/
refiningpellets
air cooling/
dedusting
pellets ready to
be packaged
hot
water
Belt dryer
barking
ambient
air
exhaust
air
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CHP – Applications: Pellet Industry
Some reference Plants
• Erdenwerk Gregor Ziegler (Plössberg, Germany): T1100-CHP – 2003
• Schachl Holzindustrie (Abtenau, Austria): T1100-CHP – 2004
• Pabst Holzindustrie (Obdach, Austria): T1500-CHP – 2005
• Sawmill Mayr-Melnhof (Leoben, Austria): 3*1500-CHP – 2005
• Bio-energie Mudau (Mudau, Germany): T1100-CHP – 2006
• Erdenwerk Gregor Ziegler (Plössberg, Germany): T2000-CHP - 2007
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The case of the Mudau plant
Average Measured operational Data :
• Hot water temperatures (to Belt dryer) : 60/80°C
• Pellet production 5 – 6 t/h
• Thermal power from ORC to Dryer : 5 MWth
• Net electric power from ORC : 1200 kWel
• Net electric Efficiency (ORC unit) : 19,2 %
• 13.500 operation hours (since 10/2006) -> 8500 hours /year
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Conclusions 1/3 (Sawmill)
•The solution based on CHP - ORC technology
coupled with drying chambers in sawmill plants is
economically interesting
•Relevant changes in biomass cost have almost no influence on the
feasibility calculation.
•Hence the investment in this kind of projects is safe against the risk
of changing in biomass price
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Conclusions 2/3 (Sawmill)
With energy value at least of 0,10 €/kWhel starting from
about 215.000 m3/year of dried production capacity
(electric energy production 1800 kWel).
Under this conditions a cogeneration plant may be a
good solution for covering the own consumption of the
sawmill plant also in countries where no support
schemes for renewable energy production are
implemented
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• The introduction of ORC technology coupled to
belt dryers in pellet production plants gives the
possibility to implement cogeneration systems
•Profitability of plants starting from 8 t/h pellet production capacity
(about 1600 kWel from ORC) - energy value 0,11-0,12 €/kWhel
•The experiences from the 10 Turboden ORC installed in the
pellet industry confirm high reliability and technical assumptions of
this study
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Conclusions 3/3 (Pellet plants)
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Via Cernaia, 10 - 25124 Brescia - Italy
Visit our web site: www.turboden.it
E-mail: [email protected]
Phone: +39.030.3552001
Fax: +39.030.3552011
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