1st Renewable Energy Technologies, LP Organic Rankine Cycle
1st RET – PSU Biomass Short Course - Greensburg
1st Renewable Energy Technologies, LP 8147 Clear Shade Drive, Windber, PA 15963 Phone: (814) 467-0431 Fax: (814) 467-8675 Email: [email protected] Web: www.1stRET.com
Organic Rankine Cycle The Rankine Cycle is a thermodynamic cycle which converts heat into work. The heat is supplied externally to a closed loop, which usually uses water as working fluid. The Rankine Cycle based on water provides approximately 85% of worldwide electricity production. Organic Rankine Cycle (ORC) is a well-known and widely used form of energy production, mostly in biomass and geothermal applications, but solar and heat recovery applications are increasing. Environmental concerns over climate change and unstable fossil fuel prices are driving the explosive growth of this efficient, clean and reliable technology. The Organic Rankine Cycle uses other working fluids instead of water: Hydrocarbons like Isopentane, Isooctane, Toluene, Silicon oil etc. The working fluid properties dictates the heat source temperature requirements. 1st Renewable Energy Technologies
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Organic Rankine Cycle Advantages À Combined Heat & Power À Highly Efficient À Commercially Proven Technology À Low Temperatures and Pressures À Low Operating & Maintenance Costs À Wide Operating Range (10 - 100% of capacity) À Fuel Diversity À Unattended Operation is Possible
1st RET – PSU Biomass Short Course - Greensburg
ORC CHP Process
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
Steam Cycle for Power Generation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
A C
Furnace Steam Boiler Steam Drum Super Heater Economizer Air Pre-Heater HP Distributor Pressure Red. LP Distributor Feed Water Tank Turbine Generator Steam Bypass Consumer Air Condenser Condensate Tank Condensate Pump Feed Pump Water Treatment
Steam System
Steam Turbine
Comb. Air to Flue Gas Treatment
1st Renewable Energy Technologies
Organic Rankine Cycle Thermal Oil System 1 2 3 4 5 6 7 8 9 10 11 12 13
A B
Heating Water System
Furnace Thermal Oil Heater Economizer I Economizer II ORC Evaporator Primary Pump Additional ORC Heat Exchanger Turbine Alternator Regenerator Condenser ORC Feed Pump Bypass- Heat Exchanger
Combustion Air to Flue Gas Filter
Biomass Furnace 1st Renewable Energy Technologies
ORC - Module
1st RET – PSU Biomass Short Course - Greensburg
85% Total Efficiency Energy In vs. Energy Out (Thermal & Electrical) 1st RET – PSU Biomass Short Course - Greensburg
ORC Energy Flow Diagram (Fuel Input to Energy Output)
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Proven European Technology > 120 Plants in Operation 1st Plant - 20+ Years Old 1st RET – PSU Biomass Short Course - Greensburg
Power Generation by Biomass
1st Renewable Energy Technologies
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Electrical Efficiency of Biomass Power Generation
1st Renewable Energy Technologies
Combined Heat & Power (CHP) ¾Efficient Hot Water
¾Renewable Electric Generation 1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
ORC Module - Generator
1st RET – PSU Biomass Short Course - Greensburg
Reciprocating Grate Combustion System À Advanced European System Designs are 98.8% Efficient À Designed for fuels up to 60% Moisture Content À Hydraulic Grate designed for Dirty & Low Energy Fuels À Water-Cooled Grate – Improves System Efficiency À Flue Gas Recirculation À Complete Combustion via Robust Computer Controls À Post Combustion Chamber À Automatic Ash Removal
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Fuel Diversity ¾Woody Biomass ¾Agriculture Waste ¾Forest Debris ¾Food Waste ¾Energy Crops ¾Municipal Solid Waste (MSW) 1st RET – PSU Biomass Short Course - Greensburg
Fuel Diversity
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Thermal Oil Heater
1st RET – PSU Biomass Short Course - Greensburg
AirMaxx4 –Heating Surface Cleaning System (8,000 Hours Per Year)
Modern firing systems allow long-term operation without interruption.
Robot with laser-based control for exact positioning of the access ports for the AirMaxx4 cleaning system.
Increasing demands on cost-efficiency increase the demands on heating surface cleaning systems.
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
ORC Plant Sizes ORC – Biomasse Fernheizwerk Schluderns Glurns District heating and electricity supply ORC – Module AD 270 TF-plus Generator output Heating water capacity
270 kWel 1,250 kWth
ORC – Biomasse Heizkraftwerk EPC-Torgau Heat and electricity supply for pellet production 2 ORC – Modules AD 1600 TF-plus Total Generator output 3,100 kWel Total heating water capacity 15,180 kWth 1st RET – PSU Biomass Short Course - Greensburg
Skid-Mounted ORC Module
1st RET – PSU Biomass Short Course - Greensburg
1st RET – PSU Biomass Short Course - Greensburg
Applications ÀDistrict Heating/Cooling ÀProcess Heat (176 - 248°F) ÀPre-Heating Steam Condensate ÀDesalination 1st RET – PSU Biomass Short Course - Greensburg
Pre-Heating Steam Condensate ÀSteam Turbine Condensate @ 120°F ÀSteam Boiler Heating System
Condensate @ 180°F ÀBiomass Use With Easy Integration ÀImproved Overall System Efficiency ÀPlus Renewable Electric Generation 1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
Low Cost Biomass Energy Output À50% MC Biomass @ $40/Ton = $5.47/MMBTU of Thermal and Electrical Energy at 85% Efficiency À Natural Gas @ $4.50/MMBTU = $5.63/MMBTU at 80% Thermal Efficiency À Coal @ $70/Ton in Large Steam Plant = $6.93/MMBTU at 33% Electrical Efficiency 1st RET – PSU Biomass Short Course - Greensburg
Renewable Energy Combined Heat & Power (CHP) Facility AD-2400 Biomass ORC – 10,570 kW Thermal & 2,400 kW Electrical Output Budgetary Economic Evaluation FACILITY CHARACTERISTICS Generator (Asynchronous): Households) Thermal Output (194 °F Hot Water): Thermal to Electrical Ratio: Overall Efficiency: Total ORC Plant Station Load: Biomass Fuel Cost (Est.): Biomass Fuel Energy Content: Biomass Fuel Annual Consumption: Biomass Fuel Hourly Consumption: Operating Availability @ Full Power: Planned & Unplanned Outages: Annual Electrical & Thermal Generation:
CHP ORC – 2.4 MWe & 36.07 MMBTU
Project Cost Excluding Land (Est.): Initial Equity & Grants (Est.) Loan: Interest Rate: Annual Interest Payment (Year 1): Footprint: Construction Time: Installed Combined kW Cost:
(245 BHP) (~1709
$11,637,300 $11,637,300 $0 for 10-Year Term 8.00% $0
1st Renewable Energy Technologies, LP 8147 Clear Shade Drive, Windber, PA 15963 Phone: (814) 467-0431 Fax: (814) 467-8675 Email: [email protected] Web: www.1stRET.com
Organic Rankine Cycle The Rankine Cycle is a thermodynamic cycle which converts heat into work. The heat is supplied externally to a closed loop, which usually uses water as working fluid. The Rankine Cycle based on water provides approximately 85% of worldwide electricity production. Organic Rankine Cycle (ORC) is a well-known and widely used form of energy production, mostly in biomass and geothermal applications, but solar and heat recovery applications are increasing. Environmental concerns over climate change and unstable fossil fuel prices are driving the explosive growth of this efficient, clean and reliable technology. The Organic Rankine Cycle uses other working fluids instead of water: Hydrocarbons like Isopentane, Isooctane, Toluene, Silicon oil etc. The working fluid properties dictates the heat source temperature requirements. 1st Renewable Energy Technologies
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Organic Rankine Cycle Advantages À Combined Heat & Power À Highly Efficient À Commercially Proven Technology À Low Temperatures and Pressures À Low Operating & Maintenance Costs À Wide Operating Range (10 - 100% of capacity) À Fuel Diversity À Unattended Operation is Possible
1st RET – PSU Biomass Short Course - Greensburg
ORC CHP Process
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
Steam Cycle for Power Generation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
A C
Furnace Steam Boiler Steam Drum Super Heater Economizer Air Pre-Heater HP Distributor Pressure Red. LP Distributor Feed Water Tank Turbine Generator Steam Bypass Consumer Air Condenser Condensate Tank Condensate Pump Feed Pump Water Treatment
Steam System
Steam Turbine
Comb. Air to Flue Gas Treatment
1st Renewable Energy Technologies
Organic Rankine Cycle Thermal Oil System 1 2 3 4 5 6 7 8 9 10 11 12 13
A B
Heating Water System
Furnace Thermal Oil Heater Economizer I Economizer II ORC Evaporator Primary Pump Additional ORC Heat Exchanger Turbine Alternator Regenerator Condenser ORC Feed Pump Bypass- Heat Exchanger
Combustion Air to Flue Gas Filter
Biomass Furnace 1st Renewable Energy Technologies
ORC - Module
1st RET – PSU Biomass Short Course - Greensburg
85% Total Efficiency Energy In vs. Energy Out (Thermal & Electrical) 1st RET – PSU Biomass Short Course - Greensburg
ORC Energy Flow Diagram (Fuel Input to Energy Output)
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Proven European Technology > 120 Plants in Operation 1st Plant - 20+ Years Old 1st RET – PSU Biomass Short Course - Greensburg
Power Generation by Biomass
1st Renewable Energy Technologies
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Electrical Efficiency of Biomass Power Generation
1st Renewable Energy Technologies
Combined Heat & Power (CHP) ¾Efficient Hot Water
¾Renewable Electric Generation 1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
ORC Module - Generator
1st RET – PSU Biomass Short Course - Greensburg
Reciprocating Grate Combustion System À Advanced European System Designs are 98.8% Efficient À Designed for fuels up to 60% Moisture Content À Hydraulic Grate designed for Dirty & Low Energy Fuels À Water-Cooled Grate – Improves System Efficiency À Flue Gas Recirculation À Complete Combustion via Robust Computer Controls À Post Combustion Chamber À Automatic Ash Removal
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Fuel Diversity ¾Woody Biomass ¾Agriculture Waste ¾Forest Debris ¾Food Waste ¾Energy Crops ¾Municipal Solid Waste (MSW) 1st RET – PSU Biomass Short Course - Greensburg
Fuel Diversity
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
Thermal Oil Heater
1st RET – PSU Biomass Short Course - Greensburg
AirMaxx4 –Heating Surface Cleaning System (8,000 Hours Per Year)
Modern firing systems allow long-term operation without interruption.
Robot with laser-based control for exact positioning of the access ports for the AirMaxx4 cleaning system.
Increasing demands on cost-efficiency increase the demands on heating surface cleaning systems.
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
ORC Plant Sizes ORC – Biomasse Fernheizwerk Schluderns Glurns District heating and electricity supply ORC – Module AD 270 TF-plus Generator output Heating water capacity
270 kWel 1,250 kWth
ORC – Biomasse Heizkraftwerk EPC-Torgau Heat and electricity supply for pellet production 2 ORC – Modules AD 1600 TF-plus Total Generator output 3,100 kWel Total heating water capacity 15,180 kWth 1st RET – PSU Biomass Short Course - Greensburg
Skid-Mounted ORC Module
1st RET – PSU Biomass Short Course - Greensburg
1st RET – PSU Biomass Short Course - Greensburg
Applications ÀDistrict Heating/Cooling ÀProcess Heat (176 - 248°F) ÀPre-Heating Steam Condensate ÀDesalination 1st RET – PSU Biomass Short Course - Greensburg
Pre-Heating Steam Condensate ÀSteam Turbine Condensate @ 120°F ÀSteam Boiler Heating System
Condensate @ 180°F ÀBiomass Use With Easy Integration ÀImproved Overall System Efficiency ÀPlus Renewable Electric Generation 1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
1st RET – PSU Biomass Short Course - Greensburg
11/18/2010
Low Cost Biomass Energy Output À50% MC Biomass @ $40/Ton = $5.47/MMBTU of Thermal and Electrical Energy at 85% Efficiency À Natural Gas @ $4.50/MMBTU = $5.63/MMBTU at 80% Thermal Efficiency À Coal @ $70/Ton in Large Steam Plant = $6.93/MMBTU at 33% Electrical Efficiency 1st RET – PSU Biomass Short Course - Greensburg
Renewable Energy Combined Heat & Power (CHP) Facility AD-2400 Biomass ORC – 10,570 kW Thermal & 2,400 kW Electrical Output Budgetary Economic Evaluation FACILITY CHARACTERISTICS Generator (Asynchronous): Households) Thermal Output (194 °F Hot Water): Thermal to Electrical Ratio: Overall Efficiency: Total ORC Plant Station Load: Biomass Fuel Cost (Est.): Biomass Fuel Energy Content: Biomass Fuel Annual Consumption: Biomass Fuel Hourly Consumption: Operating Availability @ Full Power: Planned & Unplanned Outages: Annual Electrical & Thermal Generation:
CHP ORC – 2.4 MWe & 36.07 MMBTU
Project Cost Excluding Land (Est.): Initial Equity & Grants (Est.) Loan: Interest Rate: Annual Interest Payment (Year 1): Footprint: Construction Time: Installed Combined kW Cost:
(245 BHP) (~1709
$11,637,300 $11,637,300 $0 for 10-Year Term 8.00% $0
