Codice doc. 11-COM.P-9-rev.

3 Update: 1/04/2011

Turboden ORC plants for Industrial Heat Recovery

The proven way to address environmental sustainability

Fortune 50 corporation $52.9B in 2009 sales 180 countries 206,700 employees

About us A Pratt & Whitney Power Systems Company

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UTC Power

UTC Fire & Security

Hamilton Sundstrand

Carrier

Research Center

Sikorsky

Otis

Pratt & Whitney

Large Engines

Small Engines

After market

Marine

Mobile Power

Heat to Electricity

About us A Pratt & Whitney Power Systems Company

Turboden, a Pratt & Whitney Power Systems company, is a European leader in ORC technology for the generation and cogeneration of heat and power from renewable energy and heat recovery.

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Pratt & Whitney, a division of United Technologies Corporation (UTC), is a world leader in the design, manufacture and service of aircraft engines, industrial gas turbines and space propulsion systems.
operating prot of $1.99 billion in 2010 revenues of $12.94 billion 36,000 employees more than 11,000 customers 195 countries Pratt & Whitney Power Systems (PWPS), the industrial gas turbine business of Pratt & Whitney, provides power generation and mechanical drive solutions for the electric generation, oil and gas markets, including service through the entire product life cycle PWPS also manufactures and markets the PureCycle system that can harness heat in the form of hot water from many different sources such as geothermal or oil & gas co-produced fluids, reciprocating engines, and industrial waste heat to generate clean and reliable electricity.

Turboden What We Do
Turboden designs and develops turbogenerators based on the Organic Rankine Cycle (ORC), a technology for the combined generation of heat and electrical power from various renewable sources, particularly suitable for distributed generation.

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standard size Turbogenerators from 200 kWel to 3 MWel

customized products up to 15 MWel

Turboden - 30 Years of Experience

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1984: A 40 kWel ORC turbogenerator for a solar application in Perth, Australia

1987: A 3 kWel CHP biomass ORC turbogenerator plant in Milan

2008: A 3 MWel ORC turbogenerator for waste heat in Belgium 5

The Turboden ORC Turbogenerator

ORC is a commercial technology for distributed production of combined heat and power from various renewable energy sources

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The Thermodynamic Principle: The ORC Cycle

A RM E I LO L

TH

Generator THERMAL OIL Evaporator Regenerator

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TEMPERATURE

WATER

ER WAT ENTROPY

Condenser Pump

The turbogenerator uses the hot temperature thermal oil to pre-heat and vaporize a suitable organic working fluid in the evaporator (8 3 4). The organic fluid vapor powers the turbine (4 5), which is directly coupled to the electric generator through an elastic coupling. The exhaust vapor flows through the regenerator (5 9) where it heats the organic liquid (2 8). The vapor is then condensed in the condenser (cooled by the water flow) (9 6 1). The organic fluid liquid is finally pumped (1 2) to the regenerator and then to the evaporator, thus completing the sequence of operations in the closed-loop circuit.

Advantages of Turboden ORC Turbogenerators

Technical advantages High cycle efficiency Very high turbine efficiency (up to 85%)
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Operational advantages / results Simple start-stop procedures Automatic and continuous operation No operator attendance needed Quiet operation Very High Availability (Admont over

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, thanks to the absence of moisture in the vapor nozzles

50,000 hours of operation, availability >

98%) Partial load operation down to 10% of nominal power High efficiency even at partial load Low O&M requirements: about 3-5 hours / week Long life

Layout Some Examples

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TURBODEN 7 layout

TURBODEN 18 layout

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Layout Some Examples

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ORC Applications Heat Recovery

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Biomass

Heat Recovery

Geothermal

Solar Thermal Power

Heat Recovery Turboden ORCs can produce electricity by recovering heat from industrial processes, reciprocating engines and gas turbines. The power of Turboden Turbogenerators in this application generally ranges between 400 kW and 5 MW electric.

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HR Applications / Energy Sources

Gaseous sources: Internal combustion engines exhaust gas (ORC as bottom
cycle to Diesel and gas reciprocating engines, gas turbines)

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Steel furnaces exhaust gas Cement, Glass and other non ferrous materials furnaces exhaust gas Exhaust Gas from waste incineration (civil/industrial) Liquid sources: Refineries hot streams Cooling water (or other fluids) loops in industrial processes Jacket cooling water of reciprocating engines

Condensing sources:

Refineries organic vapours to be condensed Surplus steam from production process (i.e. paper
production process)

Steam from cooling loops in industrial processes (i.e.

steel)

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HR (Heat Recovery) modules Standard Sizes and Typical Performances

TURBODEN 6 HR INPUT - Thermal oil Thermal oil nominal temperature (in/out) Thermal power input OUTPUT - Cooling water Cooling water temperature (in/out) Thermal power to the c ooling water Performances Gross elec tric power Gross elec tric effic ienc y Captive power c onsumption Net active electric power output Net elec tric effic ienc y Elec tric al generator kW kW kW 600 20,2% 25 575 19,4% async h., 3 phase, L.V. 726 20,2% 30 696 19,3% async h., 3 phase, L.V. 1.000 20,5% 38 962 19,7% async h., 3 phase, L.V. 1.370 20,4% 52 1.318 19,7% async h., 3 phase, L.V. 1.848 20,5% 60 1.788 19,9% async h., 3 phase, L.V. 2.296 20,1% 76 2.220 19,5% async h., 3 phase, L.V. C kW 25 / 35 2.340 25 / 35 2.840 25 / 35 3.840 25 / 38 5.275 25 / 40 7.065 25 / 44 9.000 C kW 260 / 150 2.970 270 / 150 3.600 270 / 150 4.880 275 / 150 6.700 280 / 150 9.000 280 / 150 11.400 TURBODEN 7 HR TURBODEN 10 HR TURBODEN 14 HR TURBODEN 18 HR TURBODEN 22 HR

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Size of plant

15 X 3 X 3,1 15 X 3 X 3,1 15 X 6 X 3,3 13 X 6 X 6,2 Single skid Single skid Single skid Multiple skid

15 X 7 X 5 Multiple skid

17 X 7 X 5 Multiple skid

*Data indicated could change taking into account the actual features of the specific project (optimization of heat recovery applicat

Modules with power outputs above 3 MW are optimised case by case

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Heat recovery from Internal Combustion Engines: heat sources

Turboden's ORC modules for heat recovery have a power output between 400 kWe up to 10 MWe: the minimum thermal power necessary to employ a Turboden ORC is approximately 2 MWt
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Exhaust gas: Typically contains between 1/4 and 1/3 of the fuel
heat, being released at relatively high temperatures (300 500 C).

ORC production reaches up to 10% of engine power output

Jacket water: very low temperature heat (< 100 C)

is released by this loop to atmosphere.

ORC production (including main plant savings) reaches up to 3 % of engine power output

Heat Recovery from Internal Combustion Engines: reference projects

Project
Pisticci I Oxon FinPower
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ORC Module
TURBODEN 18 HR SPLIT (1,8 MWe) In operation since IV quarter 2010 TURBODEN 6 HR SPLIT (0,6 MWe) In operation since IV quarter 2008 TURBODEN 6 HR DIR. EXCH. (0,6 MWe) In operation since II quarter 2009 TURBODEN 40 HR SPLIT (3,8 MWe) Under construction TURBODEN 6 HR DIR. EXCH. (0,6 MWe) Under construction TURBODEN 6 HR SPLIT (0,6 MWe) In operation since II quarter 2010 TURBODEN 6 HR (0,6 MWe) Under construction TURBODEN 10 HR cogenerative (1 MWe) Under construction TURBODEN 6 HR cogenerative (0,6 MWe) Under construction TURBODEN 10 HR (1 MWe) Under construction TURBODEN 14 HR (1,3 MWe) Under construction

Site
Pisticci (I) Pavia (I) Visano (I) Pisticci (I) Portogruaro (I) Catania (I) Herten (D)

Engines
3 x 8 MWe Wartsila Diesel engines 1 x 8 MWe MAN Diesel engine 1 x 17 MWe Wartsila Diesel engine 3 x 17 MWe Wartsila Diesel engines 1 x 7 MWe Wartsila Diesel engine

Pisticci II Cereal Docks Eukrasia

2 x 1 MWe JGS/GE gas engine + 3 x 0,8 MWe JGS/GE gas engine + 1 x 0,6 MWe JGS/GE gas engine
2 x 2,1 MWe MWM gas engine (+ additional heat from the process) 2 x 2 JGS/GE gas engine (+ additional heat from the process) Diesel engine 1 x 17 MWe Wartsila Diesel engine 4 x 4 MWe MWM gas engines

Blue Tower Ulm Kempen Mondopower HSY

Senden (D) Kempen (D) Chivasso (I) mmssuo (FIN)

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Heat Recovery from Gas Turbine: 20% addl power / reduction in specific emissions
ORC suitable for heat recovery in:
Remote/unmanned locations with variable operating loads (e.g. gas compressor stations) Peak load power stations (easy and fast start-up procedures) Heavy duty / continuous applications
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ORC Gross Power Output [kW]

9.000 8.000 7.000 6.000 5.000 4.000

TURBODEN ORCs Power output vs Gas Turbine Shaft Power Output

SGT-700 Siemens
Pel ORC % Pel ORC/Pel Gas Turbine

80%

70%
60% 50% 40%

UGT 25000 Zoyra RB211 RR FT 8 P&W LM2500 GE

SGT-500 Siemens
Mars 100 Solar Titan 130 Solar
30% 20%

3.000

2.000 1.000
0 0 5.000

SGT-200 Siemens Centaur 40 Solar

10% 0%

10.000

15.000

20.000

25.000

30.000

NOTE: Indicative values assuming ambient air temperature of 15C, Gas Turbines operating at nominal load; calculations based on Gas Turbine exhaust gas properties as reported in specific suppliers web sites.

16 Gas Turbine Shaft Power Output [kW]

Heat Recovery from Gas Turbine

Reference Case Study:
Heat recovery from Solar CENTAUR gas turbine in a Gas Compressor station in Canada
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Gas Turbine prime power: 3.5 MWe Gas Turbine efficiency: ORC electric power: 1MWe 28%

General Contractor: IST (Innovative Steam Technologies) Final Client: TransGas

Under construction, start up 1st quarter 2011

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Heat Recovery In Cement Production Process

Exhaust gas streams from cement production process:

Kiln pre-heater gas
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Clinker cooler gas

Main Exhaust Gas Characteristics:

High dust content Different operating conditions depending on mill operation, season, plant upsets, etc.

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Heat Recovery In Cement Production Process

Reference Case study: PRS gas waste heat recovery
Clinker production capacity: 5.000 ton/day Heat source: exhaust gas @ 330C Gas cooled down to 220C (extra heat used for raw
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material pre heating)

ORC electric power: ca. 2 MWe

Client: CIMAR ITALCEMENTI GROUP (Morocco) In operation since 2nd quarter 2010

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Heat Recovery In Refractory Production Process

Reference Case study: Refractory ovens exhaust gas heat recovery
Refractory production capacity: 250 ton/day
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Heat source: exhaust gas @ 500 C Gas cooled down to ca. 150 C

ORC electric power: ca. 1 MWe

Client: RHI GROUP (Radenthein - Austria) In operation since: first quarter 2009

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Heat Recovery in Steel Industry

Main exhaust gas streams available:

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Rolling, forging Strip processing Heat treatment BOF Blast furnaces

Relatively clean exhaust gas at moderate temperature Cost effective for ORC 600/800 kWe Exhaust gas: high flows, high temperatures, high dust content, large variations in operating cycle, environmental constraints Interface between process and energy recovery unit is critical

Sinter
Electric Arc Furnace

ORCs proposed where heat recovery exchangers are available

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Heat Recovery in Glass Industry

Heat source main properties:

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High exhaust gas temperature Constant operating conditions

Exhaust gas with moderate dust content

Exhaust gas must be cooled not below 200C

High temperature ORC cycle employed: ORC electrical efficiency up to 25 %

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Heat Recovery In Glass Production Process

Reference Case study: Float glass production process

Glass production capacity: 600 ton/day
Heat source: exhaust gas at approximately 500C
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ORC electric power: ca. 1,3 MWe

Final Client: AGC Glass Europe Cuneo Plant General contractor: GEA Bischoff Under construction, start up 4nd quarter 2011

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Heat Recovery from Hot Liquid streams

Power Output > 1 MWe: Turboden tailor made ORC plants Thermal power in hot liquids streams can be used directly as input to the ORC unit Cost-effective plants with ORC power greater than 1.000 kWe and liquid temperature higher than 100-120 C
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Solutions studied and optimised case-by-case.

Power Output < 1 MWe Modular/scalable 270 kWe ORC unit: PureCycle Pratt and Whitney PureCycle Cost-effective plants starting from single 270 kWe PureCycle unit (reduced investment costs) Three standard cycles to match heat sources (water, etc.) temperatures between 90 C and 150 C

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Heat Recovery Reference Case study

Example of Turboden tailor-made ORC plant for heat recovery from hot water: 3 MWe installation in Roeselare (B)
Plant type: Heat recovery from pressurized water boiler in waste incinerator
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Customer : MIROM (Roeselare-Belgium) In operation since: 2nd quarter 2008 Heat source: hot water at 180 C (back 140 C) Cooling source: water/air Total electric power: 3 MWel Net electric efficiency: 16,5% Availability: > 98%

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The PureCycle Power System

280 kW Gross Power Free fuel

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Zero emissions Renewable baseload power generation 195F 300F resource range Modular and scalable for larger plants Short lead times 24/7/365 remote monitoring High availability
* 91C 149C

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Heat Recovery Reference Example

Example of PureCycle unit in operation: heat recovery from reciprocating engine in Guatemala

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Cooling Tower

Commissioned December 2008

Operating on jacket water of 10MW reciprocating engine ~ 200kW net

Displaces expensive fuel costs Supports green initiative of customer
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Heat Recovery Data Collection Sheet

Title: Heat recovery data collection sheet T-11Other notes: . . . . . . . . .

Date: Company: Reference person: . e-mail .. tel. . Examined process/es: . Note: (*) data are mandatory for a preliminary evaluation Technical data: (*)T-1Heat Source: (*)T-2Temperature:

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Liquid .. C

Gas

Economical data (*)E-1Operating time: .. .. hours/day hours/year

(*)T-3Flow rate: .. kg/s . Nm3/hr T-4Heat source characteristics T-4aComposition: CO2 % CO % H2O % N2 % Other () % Other () % Other () % T-4bdust content: mg/Nm3 T-4cpresence of compounds potentially aggressive for the heat recovery system: T-5Minimum temperature achievable for the waste heat source . C T-6If possible, enclose a PFD T-7Average temperature at installation site: .. C T-8Height above sea level: m T-9Availability of cooling water (well, river, ...) . Temperature .. C Flow rate .. kg/s .. m3/h Notes: T-10If possible, enclose a typical daily operation diagram (flow rates and temperatures)

E-3Energy sources: E-3aElectricity: Average cost: .. /MWh E-3bMethane / natural gas: Yearly consumption: Nm3 E-3cOther fuels: . Yearly consumption: [] Average cost: .. [ / ...] E-4Possible co-generative use: temperatures: / C Additional notes: .. .. ..

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Copyright Turboden S.r.l. All rights reserved

Turboden at a Glance

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Turboden at a Glance
R&D MARKETING/SALES DESIGN Complete in-house mechanical design OPERATION & MANUFACTURING Outsourced components from highly qualified suppliers Quality assurance & Project management SERVICE Start-up and commissioning

Participation in national & Evaluation of technical EU research programs & economical feasibility of ORC power plants

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Cooperation with EU Proprietary design Universities and Research Customized proposals and own Centres to maximize economic & manufacturing of ORC Thermodynamic cycle environmental targets optimized turbine optimization Support for applications Working fluid selection & to Public Authorities for testing Green Power incentives Thermo-fluid-dynamic design and validation Implementation & testing of control/supervision software Many patents obtained

Maintenance, technical assistance to operation and spare parts service

TOOLS
In house skid mounting to minimize FEA - Finite Element site activities Analysis 3D CAD-CAM Vibration analysis Thermo-fluiddynamic programs Remote monitoring & optimization of plant operation

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Turboden Facts & Figures

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(Last update: January 2010)

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Notes

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Notes

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Notes

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Turboden s.r.l. Via Cernaia, 10 - 25124 Brescia, Italia tel +390303552001 - fax +390303552011 info@turboden.it www.turboden.it C.F./P.I. IT02582620981 capitale sociale 1.800.000 i.v. R.I.: C.C.I.A.A. di Brescia 02582620981 REA 461817