STEAM & POWER

ORC COGENERATION SYSTEMFOR YOUR MANUFACTURING PROCESS.

AT YOUR SERVICESteam & Power ORC System was conceived to satisfy many manufacturing processes requiring electricity as well as relevant amount of medium pressure steam.

FOOD & BEVERAGE CHEMICAL & PHARMACEUTICAL

TEXTILE OIL & GASPLASTIC & RUBBER

PAPER & WOOD INDUSTRY

High-temperatureORC cogeneration systemSteam & Power ORC (Organic Rankine Cycle) System is a new technical solution for the cogeneration of high-temperature heat and electricity (CHP), with a very high overall energy efficiency, directly employed in manufacturing and industrial processes.

Electric power rating from 400 kWe to 10 MWe (multiple units) CHP steam output pressure range from 5 to 30 bar CHP steam capacity range from 4 to 80 t/h (multiple units)

Why choose Steam & Power ORC System for energy efficiency?

HIGH STEAM PRODUCTION (NO LOW-TEMPERATURE HEAT)

POSSIBILITY OF COMBINING THE SYSTEM WITH OTHER COGENERATION TECHNOLOGIES

VERY HIGH OVERALL EFFICIENCY (UP TO 94% WITH NATURAL GAS COMBUSTION)

HIGH FLEXIBILITY & DIFFERENT FUEL SOURCES

HIGH EFFICIENCY AT PARTIAL LOAD DOWN TO 20%

LOW OPERATION AND MAINTENANCE COSTS

Which CHP scheme?

TOPPING CHP BOTTOMING CHP

FUEL COMBUSTION Natural Gas Poor gases and by-products Wood biomass, pellet Waste (sludge, residues etc.)

HEAT RECOVERY Gas turbines Industrial processes

NOTE Multiple heat sources can feed a single Turboden Steam & Power ORC System.

STEAM & POWER PRODUCTION

ORC working principle

The ORC turbogenerator makes use of a closed thermodynamic cycle to convert heat into electricity. The thermal power recovered from the heat source vaporizes a suitable organic working fluid, which then expands through the turbine and produces clean and reliable electric power through the alternator. Thanks to the regenerator, internal heat recovery takes place improving the cycle efficiency. Downstream from the regenerator, the organic vapour is condensed and pumped back to start the cycle again. The heat from condensation is used for steam production for manufacturing processes.

The heat input is transferred to the ORC working fluid by means of an intermediate circuit or directly via the combustion gases in direct exchange system.

* Multiple heat sources can feed a single Turboden Steam & Power ORC System.

* ORC units can produce electric and/or mechanical power

HEAT SOURCE*PROCESS

SELF-CONSUMPTION

PROCESS SELF-CONSUMPTION

(FEED WATER)

ELECTRIC POWER

STEAM

GRID

Steam & Power and circular economy

Turboden Steam & Power ORC Systems can be fed by multiple heat sources, offering an opportunity of exploiting by-products of the manufacturing facility to further reduce natural gas consumption, CO2 emissions, and avoid disposal costs.The residual wastes are thermovalorized and the resulting heat is converted into useful electricity & steam by Turboden Steam & Power ORC System. If needed, the complementary heat required can be provided by natural gas. Thus, waste that used to be a cost (for disposal) turns into a valuable asset (fuel).

STEAM & POWER

INDUSTRIAL PROCESS

PROCESS BY-PRODUCTS

Topping CHP: natural gas

Steam & Power ORC System, along with a gas-fired thermal oil boiler, can produce electricity and steam, directly exploitable in manufacturing processes.The innovative principle of Steam & Power ORC Systems is the temperature level of the cycle itself, about 100°C higher than for standard ORC units. It allows cogeneration of electricity and steam at medium pressure with a very high overall energy efficiency.

STEAM* 76%

ELECTRICITY 16%

LOSSES 8%

Example of a topping natural gas-fired configuration with a Turboden Steam & Power ORC System.

* Steam output at 10 bar(g)

Technology benchmark and comparisonCombined Heat and Power (CHP) systems are universally acknowledged as a profitable, efficient, and sustainable way of generating energy for manufacturing industries. Turboden Steam & Power ORC System is the best solution for cogeneration of medium pressure steam and electricity, ideal for industrial processes with a steam capacity from 3 to 80 t/h (multiple units) and an electricity demand between 400 kW and 10 MW (multiple units).

92% ST

18% ST50% ST

84% ST76% ST

8% LO

44% EE

28% EE

8% EE16% EE

STEAM boiler I.C. engine GAS turbine STEAM turbineST&P ORC

38% LO 22% LO8% LO 8% LO

traditional system combined steam & power systems

NOTES1. Turboden elaboration of major OEM datasheets.2. Jacket water heat for I.C. engine is accounted as losses. Legend: LO = losses EE = electricity ST = steam

Legend: ICE = Internal Combustion EngineGT = Gas TurbineMGT = Micro Gas TurbineST = Steam TurbineST&P = Steam & Power ORC

0.1 0.3 1 3 10 30

0.10.20.5

12

Electricity output [MWe]

Elec

tricit

y to

stea

m ra

tio ICE

MGTGT

STST&P

TURBODEN POSITIONING IN THE CHP MARKET

TURBODEN STEAM & POWER: A NEW COGENERATION TECHNOLOGY

Case history: Steam & Power for a dairy

THE CUSTOMERCentrale del Latte di Brescia established in 1930 with the objective of ensuring hygiene checks on milk and daily distribution to all citizens. Centrale del Latte di Brescia was the first municipal dairy in Italy to have a UHT plant for production of long-life milk. The company was the first in the world to pack UHT milk in fully recyclable PET bottles.

THE NEEDCentrale del Latte di Brescia used to produce steam by means of a traditional boiler buying electric power from the local grid. The customer decided to look at a cogeneration solution to increase the overall efficiency of the system and reduce related costs.

OUR SOLUTIONTurboden provides a turnkey solution, supplying the completeplant, from the direct exchange system between the primary heat source and the ORC working fluid to the high-temperature ORC turbogenerator. The Turboden solution perfectly fits the energy needs of Centrale del Latte di Brescia, which uses an ST&P ORC System to co-generate about 700 kW electric power and 5 ton/hour of steam at 15 bar(a) needed to pasteurize long-life milk.

“Centrale del Latte is very sensitive to clean and environmentally-friendly solutions. High-efficiency cogeneration fits in perfectly with our philosophy: for some years we have been looking for a suitable technology for our energy needs and to improve the energy efficiency of our production plant. We are sure that the synergy between Turboden and our dairy, two important companies in Brescia’s industrial context, will certainly lead to a successful project.”

Franco Dusina President of Centrale del Latte di Brescia

A typical business case

HYPOTHESIS and NOTES

1. Differential analysis of CHP technology compared to a conventional steam generation system (thermal only).2. Existing boiler efficiency 90%.3. Steam output at 15 bar(a).4. Natural gas price 25 €/MWh.5. Equivalent working hours 8,000 h/year.6. Italian scenario considering Italian incentive regulation for CAR (white certificates, tax regulations on electricity and exemption of taxes for natural gas).* Compared to fuel input.** On gross electrical output.*** Excluding civil and electrical connection.

ST&P ORC SYSTEM TD 6

Steam capacity [t/h] 6

Electrical gross output [kW] 890

Electrical gross efficiency [%] * 16

Captive consumption [%] ** 7

CAPEX [€/kWe]*** 2,500

Maintenance cost [€/kWhe] 0.005

Electricity price [€/MWh] 100

PBT [years] 3

IRR [%] 30

Bottoming CHP:revamping gas turbine

By adding Steam & Power ORC System as the bottoming cycle of a gas turbine, you can enhance the electrical output of the CHP system maintaining a valuable steam output in CHP mode.

ST&P ORC System increases the power output of the gas turbine from +15-20% Steam production in CHP is reduced by a 10-15% only Enhancing power production gives benefits to power plant sustainability

Example of a bottoming Steam & Power ORC System recovering waste heat from a gas turbine or an industrial process.

Case study: Steam & Power for a chemical industry

THE CUSTOMERThe ideal customer is a leading European manufacturer of a wide range synthetic fibres.

THE NEEDThe power plant requires about 6 MW electric power and 11 ton/hour steam at 7 bar(a).The plant is already equipped with an existing gas turbine working in cogeneration with a bottoming HRSG. Moreover, the plant needs to ensure the possibility of island mode operation in order to ensure production stability.

OUR SOLUTIONTo improve energy efficiency, Turboden supplies an ORC unit bottoming the existing gas turbine, generating an additional 1000 kW, with a valuable steam output of about 11 ton/hour.By adding the Steam & Power ORC System, the overall cogeneration plant electrical efficiency increases by 5.5%.

HYPOTHESIS and NOTES

1. Differential analysis of combined cycle respect to GT + HRSG.2. Revamping of an existing GT.3. Steam output at 7 bar(a).4. Natural gas price 25 €/MWh.5. Equivalent working hours 8,000 h/year.6. Italian scenario considering Italian incentive regulation for

CAR (white certificates and tax exemption for natural gas).* Compared to thermal input to ORC.** On gross electrical output.*** Excluding civil and electrical connection.

TOPPING GAS TURBINE

Electrical gross output [kW] 5,100

Electrical gross efficiency [%] 30.2

Exhaust mass flow [kg/s] 19.5

Exhaust temperature [°C] 545

BOTTOMING ST&P TD 8

Steam capacity [t/h] 8 from ORC +3.1 from HR

Electrical gross output [kW] 900

Electrical gross efficiency [%] * 16

Captive consumption [%] ** 5

CAPEX[€/kWe]*** 3,000

Maintenance cost [€/kWhe] 0.005

Electricity price [€/MWh] 90

PBT [years] 3

IRR [%] 35

Technical & economical features

ABOUT US

Turboden, a group company of Mitsubishi Heavy Industries, is an Italian firm and a global leader in the design, manufacture and maintenance of Organic Rankine Cycle (ORC) systems, highly suitable for distributed power generation. ORC systems can generate electric and thermal power exploiting multiple sources, such as renewables (biomass, geothermal energy, solar energy), traditional fuels and waste heat from industrial processes, waste incinerators, engines or gas turbines.

Mitsubishi Heavy Industries, Ltd. (MHI), headquartered in Tokyo, is one of the world’s leading industrial firms with 80,000 group employees and annual consolidated revenues of around 38 billion U.S. dollars (year 2018). For more than 130 years, the company has channeled big thinking into innovative and integrated solutions that move the world forward. MHI owns a unique business portfolio covering land, sea, sky and even space. MHI delivers innovative and integrated solutions across a wide range of industries from commercial aviation and transportation to power plants and gas turbines, and from machinery and infrastructure to integrated defense and space systems.

PART OF MITSUBISHI HEAVY INDUSTRIES GROUP

Turboden benefits from the Mitsubishi Heavy Industries global network in a number of ways, including: financial stability, sharing of business practices (including customer warranties) and technology development.

CAPABILITIES& EXPERIENCE

With 40+ years of experience, a global presence, 750+ MWe installations, and 400+ plants in 50 countries, Turboden is a market leader in the proprietary design and manufacturing of ORC optimized turbines.

CUSTOMERORIENTATION

Optimized solutions for each customer and a qualified service department exclusively dedicated to customer assistance.

Why Turboden?

FLEXIBILITY

SUSTAINABILITYRELIABILITY

EASY TECHNOLOGY

TURBODENORC

Simple technical features: low pressures involved, low speed turbine, limited number of stages of the turbine (≤6), self-lubricating fluids, no water required Easy and cost-effective operation & maintenance: automatic operation (no qualified operator required), minimal maintenance activities, no major overhaul (turbine not subject to erosion or corrosion), fast start-stop procedures, no chemical and water treatments, low refilling of fluid required

Range size up to 20 MW per single shaftDifferent primary energy sourcesLarge rangeabilityCogeneration or power-only modeEase of integrationIsland mode

Core system for renewable energy and energy efficiencyClean generation of power and heatReduction of CO² emissions

High availability (98%+)Long life

Feel our strengths

* **

*

Always by your side

*up to

24/7SUPPORT*

<2hREACTION TIME

97%PLANTS WITH AFTER-SALES

CONTRACTS

GLOBAL COVERAGE2 service subsidiaries and 5 international service partner companies

CUSTOMIZED SERVICESsingle contact for requests for supportstaff dedicated to on-site and remote technical supportassistance of an international network of companies able to provide technical supportwide range of services providedprompt assistance and customized after-sales servicesremote technical support using innovative toolsdedicated spare parts warehouse

FOCUSED TEAMWORK AND TECHNICAL

DECISIONS

SATISFIED CUSTOMER

REACTION PLAN:REMOTE OR ON-SITE

CUSTOMER REQUESTOR TURBODEN

PLANNED CHECKS

TREND ANALYSISWITH LOCAL

OPERATOR SUPPORT

Meet our globaland proven experience

Update November 2021

PLANTS: 409COUNTRIES: 50TOTAL CAPACITY: 750 MWeCUMULATIVE OPERATION TIME: 19 million hoursAVERAGE AVAILABILITY: 98+%

STEAM & POWER

16-C

OM

.B-1

-rev

.6

Turboden S.p.A. | Via Cernaia, 10 | 25124 Brescia | Italy

This brochure does not constitute a legal binding offer and it is subject to change without notice. All rights reserved.