Turboden woodEnergyInformationDay1

TURBODEN ORC UNITS:
A WELL PROVEN SOLUTION

FOR SMALL SCALE BIOMASS CHP PLANTS
Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

Wood Energy information day
Wednesday 19 th November 2008
The Manor House Resort Hotel , Killadeas, Co. Fermanagh
Ilaria Peretti - ilaria.peretti@turboden.it
1
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
2
Agenda
• Turboden Company Profile

• ORC unit in Biomass Cogeneration
• Technical Advantages/Results
• Sawmill plants application: viability
• Pellet plants application: key-study
• Conclusions
3
Company profile: the origin

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 1987: 3 kWel ORC turbogenerator biomass
a solar application in Perth, Australia CHP plant in Milan
4
Company profile: today

•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
5
6
Map of TURBODEN ORC units 1/2
7
T2000-CHP-Split
Pellet Plant
Map of TURBODEN ORC units 2/2
Company profile: Figures of a growing company
EMPLOYEES

90
80
12/2000 12/2006 12/2007 12/2008
70
(*)
60
50 Employees 7 51 74 103
40
30
Production 1,4 23,5 29,5 40
20
Volume (M €)
10
•(*) estimated figures as of August 31st 2008
0
1998 2000 2002 2004 2006 2008 2010
PRODUCTION VOLUME (M€)
31/08/2008 Backlog: 59 M €
40,00
35,00
30,00
25,00
20,00
31/12/2007 Equity > 5 M €
15,00
10,00
5,00
0,00
1998 2000 2002 2004 2006 2008 2010
8
9
Turboden’s new headquarters (shop and offices)
10
ORC Plants in the cogeneration process
Overall Thermal Efficiency: 98 %
Net Electrical Efficiency: 19%

100 % 79 %
Thermal Thermal power

power from to heat users
thermal oil
19 %
Net electric power
2 % Thermal losses (insulation and

generator losses)
12
ORC technical advantages Operational results
• Fully Automatic operation and
• High cycle efficiency

start - stop
• Very high turbine efficiency (up
• No operator attendance needed
to 85 %)
• Quiet operation
• Low mechanical stress of the
turbine, due to the low • Very High Availability (e.g.
peripheral speed Admont – over 50,000 hours of
• Low RPM of the turbine operation, availability > 98%)
allowing the direct drive of the • Partial load operation down to
electric generator without 10% of nominal power
reduction gear
• High partial load efficiency
• No erosion of blades, due to
• Low O&M requirements: 3-5
the absence of moisture in
hours / week
the vapour nozzles
• Long life
13
CHP – Fuels & Applications
• Fuels • Heat Consumers

• Wood biomass: sawdust, • Timber drying in sawmills.
woodchips, bark, treated wood.
• Saw dust drying in wood pellet
factories.
• Other biomass (dried sewage
sludge, straw, green cuttings, • Air pre-heating in MDF
rice husk, etc.). industries.
• District heating networks.

• Waste material.
• Refrigeration.
15
16
Sawmill plants application: viability
CHP plants with ORC units
coupled to drying chambers in sawmills

thermal
oil
electric
power
Biomass powered ORC
boiler
trunks selecting barking processing

hot
water
product packaging drying

drying
17
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
18
Technical assumptions:
Combustion system, Drying chamber process 1/2

PLANT TECHNICAL FEATURES PLANT CONFIGURATION
Combustion system Drying chamber CHP

Thermal oil boiler efficiency (including
- 90%
Split system)
Hot water boiler efficiency (including
90% -
water economizer)
Thermal oil boiler own consumption
- 25
[kWel/MWth]*
Hot water boiler own consumption
15 -
[kWel/MWth]
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
90 90
chamber (about) [ C]
* Referred to thermal oil power
19
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
20
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 1.340 3.240 3.910 5.140 6.715 9.790 12.020
thermal oil (kW)
Hot water
temperature out 90 90 90 90 90 90 90
from ORC ( C)
Thermal power
output to hot 1.108 2.637 3.191 4.148 5.426 7.920 9.700
water (kW)
ORC net electric
205 538 641 889 1.155 1.674 2.079
power (kWel)
ORC net electric
15,3% 16,6% 16,4% 17,3% 17,2% 17,1% 17,3%
efficiency
Full load
operation hours 6.500 6.500 6.500 6.500 6.500 6.500 6.500
(hr/year)
Thermal energy
supplied to the
7.200 17.100 20.700 27.000 35.300 51.500 63.100
drying chambers
(MWh/year)
Dried
production 30.000 71.400 86.400 112.300 147.000 215.000 263.000
(m3/year)
ORC net electric efficiency = net electric power / thermal power input from thermal oil
21
Assumptions of this study: economic data and values 1/2
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)
22
Assumptions of this study:
Economic data and values 2/2

• 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%
23
Economic analysis results

Constant hot water feed Temperature = 90°C. Calorific value=2,5 kWh/kg
24
25
Pellet plant application: key-study
CHP PELLET plant:
Based on ORC unit coupled to BELT dryer
electric

Thermal oil power
biomass powered ORC
boiler
thermal
oil
ambient
air
hot
water
chipping suitable granulometry;

trunks barking
UR around 40 %
exhaust
air
Belt dryer
wood selection/
chips sorting
UR < 13 %
pellets ready to pellet making dedusting/

air cooling/
be packaged press selection/
dedusting pellets
refining
26
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

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
28
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
30
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
31
Conclusions 3/3 (Pellet plants)

• 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
32
Via Cernaia, 10 - 25124 Brescia - Italy
Visit our web site: www.turboden.it
E-mail: info@turboden.it
Phone: +39.030.3552001
Fax: +39.030.3552011
33

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TURBODEN ORC UNITS:

A WELL PROVEN SOLUTION

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

• Turboden Company Profile

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

• Sawmill plants application: viability

• Pellet plants application: key-study

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

PRODUCTION VOLUME (M€)

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

Thermal Thermal power

2 % Thermal losses (insulation and

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

• Fuels • Heat Consumers

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

• District heating networks.

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

trunks selecting barking processing

product packaging drying

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

 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

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

Combustion system Drying chamber CHP

Inlet wet product moisture 40% 40%

Outlet dry product moisture 15% 15%

Drying efficiency 50% 50%

* Referred to thermal oil power

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

• Assuming a load factor of 6.500 full load operation hours per

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

CHP - Only drying chamber

Civil work 0,5

Overall (drying chamber excluded) 2,75

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

• Full load operation hours: 6500 hours/year

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

chipping suitable granulometry;

pellets ready to pellet making dedusting/

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

• 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

Doc. 08A06320_e - Copyright © 2008 – Turboden S.r.l. All rights reserved

• 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