3-1 Nicolas Bernier - Waste Heat Recovery Using Organic Rankine Cycle Turbines
3-1 Nicolas Bernier - Waste Heat Recovery Using Organic Rankine Cycle Turbines
3-1 Nicolas Bernier - 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)
Fumes loss
25 to 60 %
drying
Source : ADEME (2014)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Industrial waste heat : the example of France (3)
Typically : agro, paper, chemical industry Typically : steel mill, cement & glass factories
Liquid discharge
Gaseous discharge
Diffuse discharge
drying
Source : ADEME (2014)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Industrial waste heat : the example of France (3)
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
Source : ADEME (2014)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Industrial waste heat : the example of France (4)
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
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Industrial waste heat : the example of France (6)
1,1 TWh
250 sites
1,400 MWe potential
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Industrial Waste Heat Recovery
Purchased fuels
(oil, gas, biomass, 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.)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Organic Rankine Cycle
▻ no fuel ▻ no chemicals*
▻ no combustion ▻ no need for high pressure
▻ no emissions ▻ suitable with temperatures as low as 80°C
* hot loop
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
WHR using ORC technology in the world
In operations for 35 years, producing more than 3,000 MW worldwide!
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
WHR using ORC technology : types of activities
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
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
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Figures for a very low enthalpy waste heat recovery
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
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
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
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Comparative table between ST and ORC solutions (2)
ORC versus steam turbines technologies Financial benefits choosing ORC tech.
ST ORC ST ORC
Maintenance, OPEX High Low Overall benefits at the end of the PPA - +
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Steam and ORC turbines
LP stages
HP stages
Potential applications are not only ORC but also C02 cycle, natural gas expansion, process gas expansion, hot air energy recovery
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Various ORC applications
●
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.
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Case study : cement factory (1)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Case study : cement factory (2)
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
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
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
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Case study : WHR from biomass dryer (1)
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
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
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
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Case study : WHR from a biogas engine
Jenbacher biogas engine
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
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).
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Case study: oil wells conversion –> geothermal (1)
Ambient
temperature : 31°C
Hot water
110°C Turbine
19 kg/s
50°C
Evaporator
1580 kW
th
Condenser
Pump
40°C
90°C
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Case study: oil wells conversion –> geothermal (2)
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
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Case study: oil wells conversion – geothermal (3)
Estimate of electricity production for various flow rates and temperatures of the source
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Ship’s diesel engine heat recovery (1)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Ship’s diesel engine heat recovery (2)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Ocean Thermal Energy Conversion (OTEC)
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Waste Heat Recovery using ORC turbines
River and Marine hydrokinetic turbines
Contact details
Nicolas Bernier
nicolas.bernier@sustenea.com
+62 899 4749 259
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