Waste Heat Recovery using ORC Turbines

Nicolas Bernier, 5ft June 2018
Waste Heat Recovery

using
Organic Rankine Cycle
turbines
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Industrial waste heat : the example of France (2)
Heat balance , fuel furnace, permanent regime
Fumes loss
25 to 60 %
Fuel Loss due to openings

3 to 10 %
100 %
Useful heat
100 %
Loss due to conveyors

Loss due to walls 3 to 10 %
3 to 10 %
drying
Source : ADEME (2014)
Typically : agro, paper, chemical industry Typically : steel mill, cement & glass factories
Liquid discharge
Gaseous discharge
Diffuse discharge
drying
Useful heat
for production
Fuel
consumption
Waste heat definitely lost
Recoverable
waste Waste heat - Heating networks
Waste recovered
heat - Electricity production
heat and exported
Waste heat
recovered
on site
Energy efficiency
actions on site
Waste heat avoided
drying
paper others refineries
cardboard
Figures in brief
319 TWh : 275 TWh (industry)
44 TWh (refineries) steel and chemistry
other metals
process : furnaces, plastics
dryer, boilers
temperature > 100°C fumes, vaporized fluids non metal

agro-industry materials
3x8h
with
weekend
stops 3x8h
no weekend
Losses from
biolers’ fumes stops
Losses from
Industrial furnaces’ fumes
waste heat
>100°C
51 TWh
Industrial
waste heat
Remaining heat >100°C
from dryers 51 TWh
drying
1,1 TWh
250 sites
1,400 MWe potential
Fuel consumption Waste heat Gross power Net power

production production
drying
Industrial Waste Heat Recovery
Purchased fuels
(oil, gas, biomass, etc.)
Genset ST, ORC Heat generation

(boilers, fired heaters/furnaces, etc.)
Electricity generated
(engine, ST, ORC, etc.)
Process
Electricity purchased
(oil, gas, biomass, etc.)
ORC
Electricity
Cooling system
(cooling towers, closed loop cooling, etc.)
Heat
Cold
Surroundings
(rivers, air, etc.)
Organic Rankine Cycle
Expanding heat to power scope of possibilities
▻ no fuel ▻ no chemicals*
▻ no combustion ▻ no need for high pressure
▻ no emissions ▻ suitable with temperatures as low as 80°C
* hot loop
WHR using ORC technology in the world
In operations for 35 years, producing more than 3,000 MW worldwide!
Source : orc-world-map.org (2015)
More players since the years 2000
WHR using ORC technology : types of activities
Source : orc-world-map.org (2015)
Reminder of Organic Rankine Cycle (ORC) technology
Generator
ORC
Turbine
Waste heat
Cooling
Working fluid vaporized
(vapor phase)
Heat Dry coolers
exchanger Evaporator
Condenser
Hot loop Cold Loop
Organic Fluid Loop
Wet coolers
- thermal oil - water
- superheated water
Working fluid condensed
- (hot gas)
(liquid phase)
Pump
Figures for a very low enthalpy waste heat recovery
Comparative table between ST and ORC solutions (1)
Steam turbines ORC turbines
Hot loop
fluid purified water steam thermal oil or superheated water
pressure 20 to 300 bar 5-20 bar
temperature 250-550°C 80-330°C
chemicals yes (water purification) no
reheating device yes (water purification) no
Working fluid loop

fluid dry purified water steam (HP) « organic » fluid
possible droplets at LP stages
water consumption yes no
pressure inlet turbine 20 to 300 bar 5-20 bar
temperature inlet turbine 250-550°C 80-330°C
pressure oulet turbine < 2 bar
temperature outlet turbines 100-45°C ~60°C
CHP possible possible
Turbine
blades up to tens of stages 1 to ~15
diameter up to several meters 10 to 60 cm
rotation speed 1800-3600 rpm up to 1800 rpm
Comparative table between ST and ORC solutions (2)
ORC versus steam turbines technologies Financial benefits choosing ORC tech.
ST ORC ST ORC
Availability 80-90% 98% CAPEX + -
Load variation -5/+5% -60/+120 Installation and commissioning - +
Pressure, temperature High Low Exploitation, availability (incomes) - +
Corrosion (efficiency decrease) Yes No Maintenance, OPEX - +
Lifetime 15 20-25 Value and options at the end of the PPA - +
Water consumption, chemicals Yes No
Maintenance, OPEX High Low Overall benefits at the end of the PPA - +
Steam and ORC turbines
Steam turbine ORC turbine
LP stages
HP stages
Turbo expander: combination of a micro turbine with an integrated generator
Potential applications are not only ORC but also C02 cycle, natural gas expansion, process gas expansion, hot air energy recovery
Various ORC applications
Biogas, landfill gas Solar Biomass Geothermal

↪ Enhancement of biogas ↪ Solar CHP with CSP field ↪ Biomass to electricity ↪ Natural hot sources
engine via exhaust, water ↪ Solar CHP with CSP and ↪ Biomass CHP ↪ Medium temperature
jacket or both heat storage ↪ Isolated site wells (from 80°C)
↪ Direct biogas to electricity
conversion with boiler Renewable Energies
Industrial Waste Diesel and gas gensets Transportation Education and

Heat Recovery ↪ Efficiency enhancement via research
↪ Vessels
exhaust, water jacket or both
↪ Process Heat ↪ Railroad ↪ With boiler simulating
↪ Exhaust gases ↪ Heavy Duty Trucks heat source
↪ Waste steam Energy Efficiency
Industrial waste heat recovery
●
fumes
●
industrial process
●
excess steam
▻ cement factories
▻ still mills
▻ foundries
▻ glass furnaces
▻ refineries
▻ aluminium smelters
▻ incinerators
▻ plants treating sewage through incineration
▻ paper factories
▻ agro-industry
▻ etc.
Case study : cement factory (1)
Case study : cement factory (2)
Scope / Investment Performance

2x ATM-3000H (ORC 3000 kWe): 5.85 MUSD
Net production : 5742 kWe
Hot source equipement: 6.67 MUSD
Cold source equipement: 1.95 MUSD
ORC availability : 8500 h (97 %)
Installation services: 0.34 MUSD Global availability : 8000 h (91%)
Turnkey power plant: 14.81 MUSD Annual production : 45.936 GWh
Estimated global CAPEX : 20 MUSD Profitability

Incentives : 0
Annual OPEX : 0.5 MUSD TRI (0.08 USD/kWh): 6 years
60.0
TRI (0.1 USD/kWh): 5 years
LCOE (10 years) : 0.54 USD/kWh
50.0 LCOE (20 years) : 0.27 USD/kWh
40.0
30.0
20.0
10.0
0.0
y0 y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 y11 y12 y13 y14 y15 y16 y17 y18 y19 y20
-10.0
-20.0
Case study : WHR from biomass dryer (1)
Charcoal and pelets factory:
recovering excess heat from the dryer
200 kW Electricity
Heat exchanger Production
2,5 MW recovered
thermal power
Turbine
130°C
50°C
Evaporator
Hot water loop
30 kg/s
Cold water
Condenser 19 kg/s
Pump
110°C
30°C
ORC (Scope of the pre-quotation)

200°C
Hot air
Case study : WHR from biomass dryer (1)
Scope / Investment Performance

1x ENO-200LT (ORC 200 kWe): 350 kUSD Net production : 180 kWe
Hot source equipement: 140 kUSD ORC availability : 8670 h (99 %)
Cold source equipement: 50 kUSD Global availability : 8500 h (97%)
Shipping & installation: 40 kUSD Annual production : 1,530 MWh
Turnkey power plant: 580 kUSD
Estimated global CAPEX : 600 kUSD Profitability

Incentives : 0
Annual OPEX : 15 kUSD TRI (0.1 USD/kWh): 4- years
2,500
2,000
1,500
1,000
500
0
y0 y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 y11 y12 y13 y14 y15 y16 y17 y18 y19 y20
-500
-1,000
Internal Combustion Engines (ICE) heat recovery
●
Diesel, HFO, gas, biogas
●
Exhaust gases and possibly jacket water
heat the thermal oil with a heat exchanger
●
Approximately 10% additional electricity
is produced
Case study : WHR from a biogas engine
Jenbacher biogas engine
Gas flaring
●
ORC technology provides a solution to reduce flaring and venting
●
Low quality gases from well are diverted to a boiler (Thermal Oil Heater).
Case study: oil wells conversion –> geothermal (1)
The estimated recoverable :

- heat output is 1580 kWth
- net power output is 88 kWe 98 kWe
Electricity Production
88 kWe
Ambient
temperature : 31°C
Hot water
110°C Turbine
19 kg/s
50°C
Evaporator
1580 kW
th
Condenser
Pump
40°C
90°C
ORC (Scope of the pre-quotation) Cooling system
Case study: oil wells conversion –> geothermal (2)
Scope / Investment Profitability

ENO-100LT (ORC 100 kWe)
TRI (0.1 USD/kWh): 6+ years
- Price list: 230 kUSD
TRI (0.2 USD/kWh): 3- years
- Titanium evaporator (option): 35 kUSD
- Shipping and start-up: 25 kUSD
00Total ORC (with option): 290 kUSD
800
Not included but available in option :
600
- Cooling system (ex.: dry cooler)
400
- Installation work of hot & cold water loops
- Storage container 200
0
Estimated global CAPEX : 350 kUSD -200 y
0
y
2
y
4
y
6
y
8 10 12 14 16 18 20
y y y y y y
Incentives : 0
-400
OPEX : 30 kUSD
2,500
Performance 2,000
1,500
Gross production : 98 kWe
1,000
Net production : 88 kWe
ORC availability : 8670 h (99 %) 500
Global availability : 8500 h (97%)

0 2 4 6 8 10 12 14 16 18 20
Annual production : 748 MWh -500 y y y y y y y y y y y
Case study: oil wells conversion – geothermal (3)
Estimate of electricity production for various flow rates and temperatures of the source
Ambient temperature : 31°C

Electricity production – kW
Mass flow rate – kg/s
Ship’s diesel engine heat recovery (1)
Ship’s diesel engine heat recovery (2)
Ocean Thermal Energy Conversion (OTEC)
Contact details
Thank you for your attention!
Nicolas Bernier
nicolas.bernier@sustenea.com
+62 899 4749 259

Waste Heat Recovery using ORC Turbines

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Nicolas Bernier, 5ft June 2018

Waste Heat Recovery

Heat balance , fuel furnace, permanent regime

Fuel Loss due to openings

Loss due to conveyors

temperature > 100°C fumes, vaporized fluids non metal

Fuel consumption Waste heat Gross power Net power

Genset ST, ORC Heat generation

Expanding heat to power scope of possibilities

Source : orc-world-map.org (2015)

More players since the years 2000

Source : orc-world-map.org (2015)

Working fluid loop

Availability 80-90% 98% CAPEX + -

Load variation -5/+5% -60/+120 Installation and commissioning - +

Pressure, temperature High Low Exploitation, availability (incomes) - +

Corrosion (efficiency decrease) Yes No Maintenance, OPEX - +

Lifetime 15 20-25 Value and options at the end of the PPA - +

Water consumption, chemicals Yes No

Steam turbine ORC turbine

Turbo expander: combination of a micro turbine with an integrated generator

Biogas, landfill gas Solar Biomass Geothermal

Industrial Waste Diesel and gas gensets Transportation Education and

Scope / Investment Performance

Estimated global CAPEX : 20 MUSD Profitability

ORC (Scope of the pre-quotation)

Scope / Investment Performance

Estimated global CAPEX : 600 kUSD Profitability

The estimated recoverable :

ORC (Scope of the pre-quotation) Cooling system

Scope / Investment Profitability

Global availability : 8500 h (97%)

Ambient temperature : 31°C

Mass flow rate – kg/s

Thank you for your attention!

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