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WASTE HEAT RECOVERY

CLEAN ENERGY SOLUTIONS



WASTE HEAT RECOVERY

In the last years, the high prices of energy and the need to reduce CO2 emissions increased the importance of heat recovery applications for industrial processes. It allows transforming the recovered waste heat within processing plants into electricity or using biomass as fuel to generate significant cost savings and reduce waste.


Our Waste Heat Recovery technology in collaboration with Turboden S.A.R.L. and Mitsubishi Heavy Industries Ltd. helps contribute to energy savings and efficiency as established by European guidelines and current international protocols. Currently, the portfolio includes 265 operation plants and another 56 more in construction in more than 34 countries worldwide becoming a market leader.


The Rankine Cycle is a thermodynamic cycle which converts heat into work. The heat is supplied externally to a closed loop, which usually uses water as working fluid. The Rankine Cycle based on water provides approximately 85% of worldwide electricity production.


The Organic Rankine Cycle (ORC) today is similar to the traditional steam turbine, but, instead of using water vapour, it vaporizes a high-molecular-mass organic fluid producing electricity. The application is widely used in biomass, heat recovery and geothermal applications. The key advantages are higher electrical efficiency and no erosion of metallic parts and blades. It is preassembled onto one or more skids and can be easily transported as well.


The ORC turbogenerator uses medium-to-high temperature thermal oil to preheat and vaporize suitable organic working fluid in the evaporator. This fluid then rotates the turbine which is coupled to electricity generator resulting in clean, dependable electrical power. Given that this is a closed-cycle operation, the exhaust vapour is further used to heat the organic liquid which is then condensed in the condenser and cooled by the cooling circuit before being pumped into the regenerator and evaporator.

ORC APPLICATIONS

We design, install and maintain ORC turbogenerators in accordance to client’s specifications and industry. We produce the combined generation of electric power and heat utilizing renewable resources including waste heat from industrial processes, engines and turbines. The power generated ranges from 200Kw to 20Mw per single unit.

Capable of employing a wide range of temperatures, the system generally recover heat from industrial processes, reciprocating engines and gas turbines. The key is the ease of integration into existing processes – even with inconsistent heat sources – and complete automation leaving clients to focus on their businesses.


TYPICAL APPLICATIONS
Gas Liquid Steam/Vapor
Cement
Glass
Oil & Gas
Chemicals
Steel/Nonferrous
Pulp & Paper
Food
Waste Treatment
Thermal Oxidizens
Power Generation

Biomass is the future of renewable energy sources as it can be found nearly everywhere, stored for long periods of time and economically viable. For biomass applications, Co-Generation plants coupled with ORC turbo-generators produce both heat and electric power. The ORC split systems allow maximization of electric power production due to a more efficient utilization of thermal power from the boiler while non-split systems maximize electrical efficiency. As before, the ORC systems can be fed thermal oil, saturated vapour or superheated water.


Heat Recovery System (HRS) ORC models are capable of operating in both dissipative conditions, maximizing higher electrical output and efficiency. In Co-Generation mode, it has the ability to provide heat with a water temperature of up to 60 °C (140°F) while adjusting for seasonal thermal load and maximizing biomass utilization.


It fuels range from wood biomass, sawdust, woodchips, treat wood, bark to rice husks, straw, green cuttings and waste material.


Its applications include district heating networks, timber drying for sawmills, sawdust drying in pellet factories, air preheating in MDF factories, greenhouses, and refrigeration. (Please follow and standardize as above for applications)


INDUSTRIAL BENEFITS

The main advantages are the following:

Technical


  1. High cycle and turbine efficiency;
  2. Low mechanical stress of the turbine due to low peripheral speed;
  3. No erosion of the turbine blades, thanks to the absence of moisture in the vapour nozzles;
  4. Very long operational life of the machine due to the characteristics of the working fluid that, unlike steam, is non eroding and non-corroding for valve seats, tubing and turbine blades;
  5. No water treatment system as in steam plants is necessary.

Operational


  1. No operator attendance required with automatic and continuous operations;
  2. Quiet operation and high availability of 98%;
  3. Lower maintenance cost and long life.