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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 - ilaria.peretti@turboden.it

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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: info@turboden.it

Phone: +39.030.3552001

Fax: +39.030.3552011

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