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Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme

The Organic – Power Production from Low

Hartmut Spliethoff, Andreas Schuster Institute for Systems Technische Universität München

Electricity generation, combined heat and power Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie Systeme Contents

• Introduction – History… – Recapitulation Clausius Rankine Cycle

• State of the Art Applications – – Geothermal Power Plants

• Innovative Applications – Solar Desalination with – -heat recovery from biomass digestion plants

• Conclusion and Outlook

Electricity generation, combined heat and power 2 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme Who was the Rankine - cycle’s “father” ?

William John Macquorn Rankine * 5th July 1820 † 24 th December 1872

• Scottish physicist and engineer

• one of the founders of WJM Rankine thermodynamics • important contributions to the theory of steam

Electricity generation, combined heat and power 3 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie S ysteme Assembly of a steam

Boiler House (steam generator) Cooling Towers Turbine House Cooling Towers (, condenser, generator) Steam Turbine G Generator

Condenser Coal Stockyard Jürgen Karl

Feed Flue Cleaning M(dust removal, nitric oxide removal, desulphurization)

Electricity generation, combined heat and power 4 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie S ysteme Power range and efficiency of common power for external combustion

1000 Steam Power Plants 100

10

Organic Rankine Cycle 1

Steam Engine powerpowerpower rangerangerange [MW] [MW] [MW] 0,1 Jürgen Karl, Dezentrale Energiesysteme 0,01 0 20 40 60 80

efficiency [%]

Electricity generation, combined heat and power 5 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme

The Organic Rankine Cycle – an application for small power range

The ORC uses organic substances instead of water as • Silicone Oils • Hydrocarbons • Fluorocarbons water organic fluids

Organic fluids lead to • higher turbine efficiencies due to the higher mass flow (leakage ↓) • low maintenance operation • good part load behavior

Electricity generation, combined heat and power 6 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme

The Organic Rankine Cycle – an application for small power range and external heat source 500200 Turbine 400 4 150 4 25 bar Heat 100 bar 3 44 2 3 4 300 22 3 Exchanger4 G Generator 22 33 100 10 bar Boiler Steam 200 10 bar 55 3 5 5 bar Turbine G 11 temperaturetemperature [°C] [°C] 2 temperaturetemperature [°C] [°C] 50 0 1 bar 6 0 0 6

100 2 2 4

6 6 8

Generator , 4 , 6

, ,

, biomass boiler , , , , 8

0 0 0

0 0 0 1 = 0 0 1 = x 5 0 x p=1 bar 5 geothermal heat 0 p=0,05 bar 5 Condenser 0 … District Heating Network 1,00,0 1,22,0 1,44,0 1,66,0 1,88,0 10,0 2,0 6 spezific entropy [kJ/kgK] Cooling Tower spezific entropy [kJ/kgK] 1 0 Condenser 1 0 Availaible in a power range up to 1500 MW…kW … Feed PumpFeed Pump (dust removal, nitric oxide M removal,M desulphurization)

Electricity generation, combined heat and power 7 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme

ORC withwithoutrecuperator recuperator 200

150 25 bar 4 2 3 G 100 10 bar

5 5 bar 5 1 temperaturetemperature [°C] [°C] 50 0 66 2 4 , , 6 8 0 0 , , = 0 0 5 x p=1 bar 0 6 1,0 1,2 1,4 1,6 1,8 2,0 spezific entropy [kJ/kgK]

• Expansion does end in the area of superheated steam 5 M • Sensible Heat of steam ( 5 -6 ) can be used for preheating the liquid working fluid

Electricity generation, combined heat and power 8 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme

State of the Art Applications

Electricity generation, combined heat and power 9 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme

ORC Unit from Turboden, Brescia Italy

• Units from 500 kW up to Rekuperator 1500 kW available Condenser • Standardized Product

Evaporator

Turbine Generator Feed Pump

• Units are delivered completely assembled to installation site

Electricity generation, combined heat and power 10 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme

Biomass Combustion Sauerlach – 700 kW el

Thermo oil loop

G Toblach – 1500 kW el

Organic Rankine Cycle Fußach – 1100 kW el

Electricity generation, combined heat and power 11 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme

Insertion

• dependency of electric efficiency of exhaust gas losses of biomass boiler • flow temperature / return temperature thermo oil 270 °C / 220 °C

Electric Efficiency 10…12 % Manufacturer information of 16…18 % don’t include the furnace

Electricity generation, combined heat and power 12 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme Geothermal Power Plants

ORC Return System Cooler 28°C Water processing www.geothermie.de

15-110 m³/h 21°C, 120-395 m³/h Altheim 1000 kW el

Well www.geothermie.de

Neustadt-Glewe 210 kW el

98°C

Bore Hole Injection Hole

Electricity generation, combined heat and power 13 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme

Innovative applications

Electricity generation, combined heat and power 14 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie Systeme Innovative stand-alone solar desalination system with an Organic Rankine Cycle

Collector Loop

Organic Rankine Cycle Osmosis Process

Electricity generation, combined heat and power 15 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme Design Criteria for ORC with solar heat

• Scroll expander for mechanical power in the range of 10 kW • Scroll expander is a positve displacement expansion 5,6 R227 R245fa 5,4 • Different working fluids 5,2 R236fa offer nearly the same 5,0 efficieny 4,8 R134a • Fluid with efficiency 4,6 4,4 maximum at the lowest

cycle efficiency[%] 4,2 posssible temperature fits 4,0 best 50 75 100 125 150 live steam temperature [°C]

Electricity generation, combined heat and power 16 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme Status of the project

• The project is succesfully finished • The expander efficiency is between 60 and 70 % over a wide operation range • The cycle efficiency is around 4 % • The fresh water production is approximately 320 l/h with a thermal input of 35 The research was done in the framework kW of the project RO-Solar-Rankine (COOP- CT-2003-507997) funded by the European Comission. Therefore the TU München is much obliged.

Electricity generation, combined heat and power 17 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie Systeme Waste-heat recovery from biomass digestion plants recovery with low temperature ORC

• Gainful use of the excess heat of the IC engine is important for the Organic Waste economic and energetic efficiency Manure Energy Crops • Only 20…25 % of the waste heat of the engine is needed for heating Desulphurization Grid the digester Biogas IC engine • The characteristics of heat demand and the location of the digestion plants is hindering for Biogas the use of waste heat in district Fermenter tank heating networks

enhanced electricity production by the application of ORC ORC System

Electricity generation, combined heat and power 18 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie Systeme Case Study for biomass digestion plant Thermo oil loop

Test Rig at TUM

IC engine

Organic Rankine Cycle

Electricity generation, combined heat and power 19 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie Systeme Case Study for biomass digestion plant

• Combustion Engine 555 kW Deutz TCG 2016 V12

• Electrical Power 537 kW el • Exhaust gas temperature of ~ t 490 °C C 5 O.R. • Additional Power production of Ct 35 kW el equivalent to an 6 efficiency gain of 2.6 % t C • With an interest rate of 5 % and 7 t 7.500 full load hours electricity 8 C production cost of 5.65 €- Ct Ct/kWh can be reached 9

Electricity generation, combined heat and power 20 Strasbourg, 14 -16 September 2006 Lehrstuhl Prof. Dr.-Ing. H. Spliethoff Energie

Systeme Conclusions:

• Organic Rankine Cycles are a modification of the well known Clausius Rankine Cycle

• The use of organic fluids offer various advantages

• The ORC technology for electricity production from biomass and geothermal heat is state of the art

• ORCs are also suitable for waste-heat recovery and power production from solarthermal heat – these applications are subject of further research

• ORC linked with Reverse Osmosis is a promising possibility for seawater desalination

Electricity generation, combined heat and power 21 Strasbourg, 14 -16 September 2006