S - diegm

Transcript

S - diegm

Gli impianti ORC per la produzione di energia elettrica da fonti
geotermiche: la tecnologia innovativa di Turboden
Joseph Bonafin – Sales Manager Geothermal
11 Maggio 2015
[email protected]
Copyright © – Turboden S.r.l. All rights reserved
Multidisciplina:
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Termodinamica
Meccanica delle costruzioni
Fluidodinamica delle turbo-macchine
Chimica (fluido di processo)
Chimica (fluido geotermico)
Geologia / Geofisica
Ingegneria dei pozzi
Idraulica
Elettrotecnica
Tecnologia delle componenti
Ingegneria civile / strutturale
Accettabilità sociale
Economia
Finanza
2
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
La storia e le referenze di Turboden
Fondamenti e statistiche
La risorsa geotermica: casi applicativi
Termodinamica: esempi di cicli ORC utilizzati in
geotermia
Descrizione tecnica delle componenti di impianto
Le fasi del progetto geotermico: dall’esplorazione allo
start-up
Cenni economici (Capex / Opex) e tipico Business
Plan
Business development dei mercati geotermici: cenni
ai mercati e alla competizione
Riferimenti
3
ORC early development : the starting person
Prof. Gianfranco Angelino,
Politecnico di Milano
during meeting for the Almeria Solar
Platform of S.José, California 1978.
- Started
Research on ORC in the
sixties
- Envisaged
many of the future
developments of ORC concept
4
30 Years of Organic Rankine Cycle Development
1970 – 80:
• Studies on many ORC configurations (for primary
Angelino
generation/ automotive/ heat recovery) and many
Macchi
Gaia et al. working fluids, including CO2.
• Consultants to Ansaldo, mainly for the Almeria Solar
Platform and other solar applications
3 kW ORC for flat plate solar collectors field of
Ansaldo, Genoa – featuring gravity circulation
3 kW turbine,
single stage
1980 TURBODEN IS FOUNDED by M. Gaia
5
6
3 kW ORC fed by hot water
from solar flat plate collectors
1980 – Working fluid
tetrachloroethylene
Experimental
miniaturised
centrifugal
radial turbineFluid : perfluoro
decaline
Wood log powered
3 kW ORC, 1988
W.fluid: siloxane
7
35 kW, Solar Perth,
Australia 4 stage
turbine
8
2 X 100 KW Geothermal
KAPISYA – Zambia1988
1.3 MW Geothermal plant for
Enel Castelnuovo V.C. 1992
9
1996 – Heat Recovery unit in Torbole,
Italy Source: exhaust gas from a
Cupola Furnace.
A cascaded ORC concept with
Siloxane and Perfluoropentane
working fluids
Direct air cooled condenser
1997 – Biomass unit
for the Swiss Army,
300 kW, in Bière,
Switzerland, source:
300 ° C Thermal Oil
10
Turboden has more than 300 ORC binary plants worldwide...
…with more than 6 millions cumulated
hours
Average availability is 98+% on 240 plants with
more than 6 Millions cumulative operation
working hours so far
12
A history born in the academia and then evolved into an
international group
• Prof. Mario Gaia makes experience in
the field of ORC within his research
group at Politecnico di Milano
• 1976 – First prototype of a solar
thermodynamic ORC
• Turboden installs ORC biomass plants,
especially in Austria, Germany and Italy
• Turboden plans to enter new markets, with
focus on North America
• 2013 - MHI acquires the majority
of Turboden. Italian quotaholders
stay in charge of management
• Today - Over 290 ORC plants in
the world, over 240 in operation
• First heat recovery applications
’60-’70
1980-1999
2000-2009
• 1980 – Prof. Mario Gaia founds Turboden
to design and manufacture ORC
turbogenerators
• Turboden develops research projects in
solar, geothermal and heat recovery
applications
2009-2013
2015…
• 2009 – Turboden achieves 100 plants sold
• United Technologies Corp. (UTC) acquires the
majority of Turboden’s quota. PW Power Systems
supports Turboden in new markets beyond Europe
• UTC exits the power market forming strategic
alliance with Mitsubishi Heavy Industries
• 1998 – First ORC biomass plant in
Switzerland (300 kW)
13
Turboden – a Group Company of MHI
Energy &
Environment
Energy & Environment
the largest segment of MHI
over $12 billion (in fiscal 2013)
Mitsubishi Heavy Industries
is one of the world leading
heavy machinery
manufacturers, with
consolidated sales of over $32
billion (in fiscal 2013)
Foundation July 7, 1884
Providing optimal solutions
in the energy-related
fields of thermal power, nuclear
energy and renewable energy in
different environmental areas and
for Chemical plants & other
industrial infrastructures elements.
Commercial Aviation
& Transport Systems
Delivering
advanced land, sea and air
transportation systems,
including civilian aircraft,
commercial ships and transit
networks.
Machinery, Equipment
& Infrastructure
Providing a wide range of
products that form the foundation
of industrial development,
such as machine tools, material
handling, construction machinery,
air-conditioning and
refrigeration systems.
Integrated Defense
& Space Systems
Providing advanced
land, sea and air defense systems,
including naval ships,
defense aircraft, launch vehicles and
special vehicles,
as well as space-related services.
14
Leading companies in the geothermal industry
> 3 GW of geothermal plants
ORC Units up to 40
MW per single
generator
15
Diverse applications with an extended
size range
Temperature
LOW (> 100 °C)
Geothermal
Heat
Recovery
Biomass
Cogenerative
(CHP)
Biomass /
Solar
Power Only
(HRS)
MEDIUM (< 200 °C)
HIGH (> 200 °C)
1 ÷ 40 MW
0.2 ÷ 20 MW
0.2 ÷ 15 MW
0.2 ÷ 15 MW
16
The Headquarter and facilities
Turboden facilities:
• 1 Headquarter + Turbine Assembly in Brescia
• 1 Workshop in Flero
• 1 R&D office in Milano
• 1 After Sales Office in Munich
• 1 Sales and Workshop in Ankara
17
Turboden Headquarter in Brescia
18
Overhead crane bridge moving
on-skid-mounted Turboden units
19
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
geotermia
start-up
Plan
Riferimenti
20
90% of earthquakes among ring of fire
21
Heat gradient
22
Average heat gradient in heart’s
crust: 3 °C / 100 m
23
24
25
Capacity - Project type
26
27
28
29
Lindal diagram
30
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
geotermia
start-up
Plan
Riferimenti
31
Turboden + MHI: Ranges of Application
STEAM
TURBINE
Stability limit for ORC fluid
300
HIGH ENTHALPY
GEOTHERMAL ORC
200
SIZE TOO SMALL
RESOURCE TEMPERATURE °C
400
100
MEDIUM TO LOW
ENTHALPY ORC
TEMPERATURE TOO LOW
0
10
100
1000
10000
OUTPUT POWER kW
32
Binary Plant Schematic
No standard heat/cooling sources → highly customized solutions
33
Ideal cycle
No engine
operating
between two heat
reservoirs can be
more efficient
than a Carnot
engine operating
between those
same reservoirs
Similar to the Carnot cycle that optimises heat engines operating between two constanttemperature sources, the Lorenz cycle (or triangular cycle) optimises heat engines
operating between two gliding-temperature sources by adjusting the thermal capacity of
the working fluid to that of the finite-capacity sources; i.e., Lorenz's cycle has four
processes (like Carnot's cycle): isentropic compression, heating at constant thermal
capacity matching that of the heat source (and its temperature variation), isentropic
expansion, and cooling at constant thermal capacity matching that of the heat sink (and
its temperature variation).
34
Simplified Efficiency Calculation / Power
Estimate
GEOSIMPLE
BLUE = Input
BLACK = Calc.
S.I. UNITS!!!
Project
Date
Country
Example
10/05/2015
it
Unit converter
°F --> °C --> gpm --> l/s -->
°C
°F
l/s
gpm
83,0
Tcold in °C
8
Flow rate geofluid
Flow rate geofluid
Density
CP geofluid
Thermal Power
available
Eta ORCnet/Eta
Lorentz
Eta ORCnet
NET Power
Tcold out LMT Thot out Thot in LMT
°C
°C
°C
cold
hot
20
14,0
45
140 90,4
110
l/s
106
kg/s
0,964 kg/l
@
4,195 kj/kg/K @
42260
eta Lorentz
21,0%
eta Carnot
31,9%
28,3
1540
32,0
0
24409
Average Temp Equivalent Content
[°C]
NaCl [g/l]
92,5
92,5
0
0
kW
56%
11,8%
4978
Eta Lorenz = 1 – (LMTcold/ LMThot)
35
From a pressure cooker to a Rankine cycle!
2. Expander
Cooling
1. Evaporator
3. Condenser
4. Pump
Heating
36
The Thermodynamic Principle: the ORC Cycle
TEMPERATURE
Turbine
Generator
4
3
Evaporator
5
2
1
GEOFLUID
CIRCUIT
Condenser
COOLING
CIRCUIT
Preheater
Pump
HEAT
The turbogenerator uses geothermal water to pre-heat and vaporize a suitable organic working fluid in the
evaporator (2→3→4). The organic fluid vapor powers the turbine (4→5), which is directly coupled to the
electric generator through an elastic coupling. The vapor is then condensed in the condenser, cooled by water
or air (5→1). The organic fluid liquid is finally pumped (1→2) to pre-heater and evaporator, thus completing the
sequence of operations in the closed-loop circuit.
37
Dry steam plant
38
Single Flash Steam Plant
39
Flash steam plant
40
Double Flash Steam Plant
41
Flash cycle  combined cycle?
42
Combined Flash cycle + Brine ORC cycle
ORC
43
Combined Flash cycle + Brine ORC cycle
44
Integrated Flash cycle + ORC bottoming
cycle
ORC ?
ORC ?
45
Integrated Flash cycle + ORC bottoming
cycle
46
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
geotermia
start-up
Plan
Riferimenti
47
ORC Design Considerations
Working fluid selection is influenced by many factors
Cost
Enthalpy drop
&
flow rate
Pressure levels
Environmental friendliness
Heat input curve
OPTIMAL FLUID
Flammability
changes
from case
to case
48
Advantages of Organic Fluid vs Steam
• SHAPE OF SATURATION CURVE
T
Superheated expansion, no liquid drops
hit the blades
S
• FREE POSITIONING OF THE CYCLE WITH
RESPECT TO CRITICAL POINT OF FLUID
Good matching to heat source
T
T
Q
S
T
T
S
Q
49
• Most geothermal applications are for liquid dominated systems
• The geothermal fluid is preferably maintained in liquid phase
Hence it is important to exploit efficiently the variable temperature heat source
50
Evaluation of the proper cooling system: wet Vs dry
AVAILABLE
WATER CONDENSERS
EVAPORATIVE TOWERS
EVAPORATIVE
CONDENSERS
MAKE UP
WATER
AIRCOOLERS
AIR CONDENSERS
NOT
AVAILABLE
Evaporative towers
Smaller footprint
Lower noise emissions
Fresh water consumption
Chemical water treatment → operation cost, environment
Air condensers
Larger footprint
Higher noise emissions
No water needed
Virtually no environmental impact and low operating costs
Critical issues
Investment costs: initial / overall
Generated yearly output, linked to gross power and
parasitic loads
51
Performances? ….Cost???
INPUT
OUTPUT
1. Scope of supply / delivery terms? …
1. …Turboden preference depends on
market
2. Water Temperature (in / out)? …
2. Working fluid - Cycle
3. Target size (MW)? …
3. …Minumum interesting 1 – 2 MWel
4. Steam and NCG % in weight? …
4. Working fluid - Cycle
5. Type of cooling system? …
5. Costs - Procurement
6. Water chemistry? …
6. Cycle - Performances
7. Ambient temperature / conditions?…
7. Performances - Cooling System
8. …other Framework (e.g. incentive
scheme and price of electricity),
etc..? …
8. Costs – Working Fluid - Cycle
52
Optimisation – variable heat sources
• Left: High heat input, low average input temperature  lower cycle efficiency
Pqin= 79 MWth; Etanet=9,1%, Pnet = 7,2 MWel
• Right : Low heat input , high average input temperature higher cycle efficiency
53
Optimisation – variable heat sources
• Left: heat input shape adapted to shape of heat source (R134a)
• Right :squared heat input shape (Isobutane)
54
Optimization – variable heat sources
• There is an optimum value that depends on the frame conditions and on
the employed technical solution
• In general a shape of the heat input curve that matches the source is
helpful in obtaining an optimal trade off between cycle efficiency and
recoverable input heat
• In practice the optimum design point depends also on economical
considerations (heat exchanger cost, fluid cost, etc.) and frame conditions
(available cooling flow, resource cooling, etc).
55
ORC Cycle with both Steam and Brine
(low NCG)
160
GEOTHERMAL STEAM
GEOTHERMAL
BRINE
140
n-Pentane
100
T [°C]
120
80
60
40
Air
20
0
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
Q [kW]
«S» Project Kyushu Japan / example of
«rectangular» cycle
56
(high NCG) – TQ diagram
180
Turkish Project /
example of
«triangular» cycle
GEOTHERMAL STEAM
170
160
GEOTHERMAL BRINE
150
140
130
120
110
100
N-BUTANE
90
80
70
60
50
40
30
COOLING AIR
20
10
0
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
57
(high NCG) – Ts diagram
160
150
140
130
120
100
Temperature °C
110
90
80
N-BUTANE
70
60
50
40
30
20
10
0
0
200
400
600
800
1000
1200
1400
1600
1800
Entropy kJ/kgK
58
Two Level Cycle
140
140
120
120
Geothermal brine
Geothermal brine
100
80
T [°C]
80
T [°C]
100
60
60
HFC 245-fa
HFC 245-fa
Isobutane
HFC-134a
40
40
20
20
Cooling air
Cooling air
0
0
0
10000
20000
30000
Q [kW]
40000
50000
0
10000
20000
30000
40000
50000
Q [kW]
59
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
La risorsa geotermica: casi applicativi con cicli ORC
geotermia
Descrizione delle componenti di impianto
start-up
Plan
Riferimenti
60
ACC
Heat Exchangers
ACC
Turbogenerator
Wells
61
Power Plant Components
BOP (Balance of Plant):
1. Gathering system (valves, separators, pumps, accumulators, piping)
2. Reinjection system (piping, reinjection pumps)
3. Step-up / Step-down transformers
ORC (Turboden battery limits)
1. Turbine (axial, multistage, 1500-3000 rpm)
2. Electrical Generator (synchronous / asynchronous 2 / 4 poles)
3. Heat Exchangers: pre-heaters / evaporators / regenerator (if
applicable)
4. Direct Condenser (Air cooled condenser, Water Cooled Condenser)
5. Cooling system (Air cooler, Wet Cooling Tower)
6. Piping (geothermal / fluid process)
7. Control Valves
8. Safety valves
9. ORC pumps (horizontal / barrel vertical), eta 0,75 – 0,8
10. Auxiliaries
a) Lubrication unit (air / water to oil)
b) Auxiliaries cooling
c) Instrumentation and control system
d) Electrical cubicles / cables
62
Heat Exchangers: shell & tube TEMA type
63
Air cooled Condenser
64
25 MW module layout
Optional Expansion of WCC and Cooling Tower
Heat Exchangers / Turbines – Generator skid / Recuperators
65
OPTION: Hybrid cooling system
Pnet vs Air temp
28000
27000
26000
25000
Ibrido
42 ACC
23000
22000
50 ACC
21000
Net Power kW
24000
20000
19000
18000
17000
16000
15000
14000
13000
12000
11000
10000
9000
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
45,0
Ait temperature °C
66
25 MW Module Process
2 x 12,5 MW Identical and Independent units coupled to the
same 25 MW Generator mean:
• Redundancy
• Flexibility
• Easier Maintenance Procedures
67
The Geothermal fluid cycle
1. From production line
Geothermal water and
steam enter into the
evaporator @ 165 °C:
the steam is condensed
and the CO2 vented,
2. The water and the
condensate are cooled
down to 80 °C and given
to reinjection line.
The n-butane cycle
5. The n-butane is
expanded in the Turbine
coupled to the 25 MW
Generator
4. The n-butane is
evaporated at 140 °C in
the evaporator
2. The n-butane is
pre-heated in the
recuperator
3. The n-butane is
heated to 140 °C in the
preheater
6. The n-butane is
condensed after
regenerator in the ACC
@ ambient temperature
1. The n-butane is
pumped @ 33 bar in the
69
preheater
Our Turbine R&D Manager
and a tested rotor under inhouse analysis
70
5 MW 3000 rpm
Turbine skid
with gear box
71
In 15 years the maximum power output per
single shaft has grown almost by 20 times
Units sold/under
discussion
20000
Single shaft sold units power output over time
kW
Maximum power
output available
18000
16000
14000
Plants under
discussion
12000
10000
8000
6000
4000
2000
0
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
72
Technical Advantages of Turboden
proprietary Turbine & Process
A PROVEN SOLUTION
• The design of the turbine (casing, blading) is carried out by Turboden
representing the core know-how since its foundation in 1980
• 290 Turboden ORC turbines successfully implemented with sizes from
200 kW to 15 MW
• Proven experience with 8 different ORC fluids
• Axial geometry is a traditional configuration, the most widely adopted in
turbomachinery design
• Axial is the reference design for ORC, proven with millions of working
hours worldwide
Turboden AX-Turbines
from 500 kW to 18+ MW
A MORE EFFICIENT CHOICE
• Average turbine isentropic efficiency: 85 to 88 %
• Multi stage (4- 6 stages) axial turbines are less sensitive than radial ones
to discharge pressure variations, showing nearly constant efficiency over
wide range of operating conditions
A RELIABLE TURBINE
• Average plant availability > 98% on all the Turboden fleet
• Robust design, low rpm, and strict quality tests
• Patented seals & bearing replacing system ensures short maintenance
procedures
• Specialized local staff for maintenance
• Construction: Overhung cantilever (Turboden standard) allows easier
maintenance
• Operating speed: From 1500 rpm to 3000 rpm
73
Effect of seasonal temperature variation
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
GEOTHERMAL STEAM
GEOTHERMAL BRINE
COOLING AIR
0
50000
100000
150000
200000
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
GEOTHERMAL STEAM
GEOTHERMAL BRINE
COOLING AIR
0
50000
100000
150000
200000
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
GEOTHERAL STEAM
GEOTHERMAL BRINE
COOLING AIR
0
50000
100000
150000
200000
74
Effect of seasonal temperature variation
NOMINALE
INVERNO
ESTATE
Fluid
n-butane
n-butane
n-butane
Qin kW
150792
159900
135612
Thot liq in °C
Thot liq out °C
165,0
79,5
165,0
73,1
165,0
90,1
mhot liq kg/s
319,5
319,5
319,5
Phot vap in bar(a)
9,35
9,35
9,35
Thot vap in °C
Thot vap out °C
164,8
133,2
164,8
133,0
164,8
134,6
mhot vap kg/s
30,67
30,67
30,67
Pgross kW
25682
29628
18252
Pnet ORC kW
23247
27184
15840
hgross
17,0%
18,5%
13,5%
hnet ORC
15,4%
17,0%
11,7%
Paux ACC kW
1268
1342
1221
Paux cooling total kW
1268
1342
1221
Pnet plant kW
21979
25843
14619
hnet ORC
14,6%
16,2%
10,8%
Condensation °C
Air 19-29,6
Air 3-14
Air 40-51,2
Qout kW
126592
131473
118918
US lato caldo kW/K
12561
12444
12561
US rigeneratore kW/K
1030
1030
1030
75
Net Power Vs Flow Vs Air Temperature
35.000
30.000
NETelectrical power kW
25.000
1638
1512
20.000
1386
1260
1134
15.000
1008
882
756
630
10.000
5.000
0
-15
-10
-5
0
5
10
15
Air temperature °C
20
25
30
35
40
76
Layout – Some Examples
77
Layout – Some Examples
78
Geothermal CHP: Different possible schemes
PARALLEL
TEMPERATURE
4
3
CONDENSATION
2
1
4
3
5
TEMPERATURE
5
TEMPERATURE
CASCADE
2
1
HEAT
HEAT
•
•
•
In Parallel (Traunreut, Altheim, Simbach-Braunau, Afyon)
In Series (cascade uses)
From the Condensation Heat (classic cogeneration concept, LowBin)
4
3
5
2
1
HEAT
Existing Geothermal District Heating Systems can be improved!
79
Optimized features
implemented
1. District heating
2. Non flammable fluid
3. Minimized foot-print
5. Durably technically tight system
TEMPERATURE
4. Super low-noise equipment
6. Leakage monitoring
7. Super Duplex Steel
8. Redundancy: cycle & critical parts
9. Redundant instruments
HEAT
OPTIMUM SOLUTION
10.Scada PCS station fully
integrated
11.Island mode capability
MANY CONSTRAINTS
12.Dynamic Grid regulation support
80
Turboden Geothermal Plants in Bavaria
Kirchstockach:
5,6 MWel
Dürrnhaar:
5,6 MWel
1 km
Sauerlach:
5,6 MWel + 4 MWth
81
Reference Plant - Sauerlach
Plant type: Two level cycle geothermal unit
Customer: SWM - StadtWerke München (public utilities company)
Location: Bavaria, Germany
Started-up: February 2013
Heat source: geothermal fluid at 140 C
Cooling device: air condensers
Total electric power: 5+ MWel plus 4 MW th decoupling for district heating
Working fluid: refrigerant 245fa (non flammable)
Off grid mode capable
82
Reference Plant - Dürrnhaar
Customer Name: Hochtief Energy Management GmbH
Location: Dürrnhaar (München)
Total electric power: 5,600 kW
Started-up: December 2012
Scope of supply: EPC contract for the complete ORC unit, including the Air
Cooled Condenser and the geothermal balance of plant
83
Reference Plant - Kirchstockach
Customer Name: Hochtief Energy Management GmbH
Location: Kirchstockach (München)
Started-up: March 2013
Scope of supply: EPC contract for the complete ORC unit,
including the Air Cooled Condenser and the geothermal balance of plant
84
Reference Plant - Traunreut
Customer Name: Geothermische Kraftwerksgesellschaft Traunreut mbH
Location: Traunreut (Bavaria)
Total thermal power: 12,000 kW (to the District Heating)
Status: Under Construction
Scope of supply: Supply of the complete ORC unit,
including the Air Cooled Condenser and control system of geothermal site
85
Reference Plant - Enel supercritical
Plant type: geothermal prototype with supercritical cycle
Customer: Enel Green Power
Location: Livorno, Italy
Started-up: March 2012
Heat source: hot water at 150 C nominal
Cooling device: ‘dry & spray’ condenser
Total electric power: 500 kWel
Working fluid: refrigerant (non flammable)
86
Geothermal Project “S” 5 MW
Owner: NEECO - Japanese Utility Company (location:
Kyushu Island/ Japan)
Project schedule: Award: 2013/9; Delivery: 2014/9,
Startup 2015
Heat source: hot water / steam at 142,8 C after
separator
Working fluid: n-pentane
Electric power output at generator terminals: 5
MWel
Installation: Outdoor – H2S environment
87
New geothermal project in Afyon
Plant type: geothermal
Customer: AFJET (Afyon Jeotermal)
Delivery date: 2016
Heat source: geothermal brine @110 C  Coupled to Geothermal District
Heating
Cooling device: Cooling Towers
Total electric power: 3 MWel
Working fluid: refrigerant
Overall there are currently 5 Turboden ORC projects ongoing
in Turkey. 2 units (5.5 MWel and 1 MWel are currently in
operation
88
Last Geothermal Reference in Turkey
Turboden awarded a contract for the supply
of a 25 MW geothermal plant in Morali, Aydın
Customer name: Karizma Enerji
Commissioning: 2016
89
Early Demonstration Projects
Location: DAL – Kapisya, Zambia
Year: 1988
Heat source: Geothermal fluid at 88 C
Total electric power: 2 x 100 kW
Location: Castelnuovo Val di Cecina, Italy
Year: 1992
Heat source: Geothermal fluid at 114 C
Total electric power: 1.3 MW
Plant type: geothermal low enthalpy, coupled with a geothermal district heating system
Location: Marktgemeinde, Altheim, Austria
Started up : March 2001
Still a reference
Heat source: hot water at 106 C
Cooling source: cold water from a nearby river (cooling temperature 10/18 C)
Plant type: geothermal, 1st EU operating plant on EGS (Enhanced Geothermal System)
Location: Soultz-sous-Forêts, Alsace, France
Started up: II quarter 2008
Total electric power: 1.5 MW
Still a reference
Plant type: geothermal low enthalpy, coupled with a geothermal district heating system
Location: Simbach – Braunau, German-Austrian border
Started up: III quarter 2009
Design electric power: 200 kW
90
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
geotermia
start-up
Plan
Riferimenti
91
What we do
R&D
Sales/marketing
• Participation in national • Pre-feasibility
& EU research
studies: evaluation of
programs
technical &
economical
• Cooperation with EU
feasibility of ORC
Universities and
power plants
Research Centres
• Customized
proposals to
maximize economic
• Working fluid selection
& environmental
& testing
targets
• Thermo-fluid-dynamic
design and validation
• Institutional
• Implementation & testing Relationship and
Lobbying for tariffs
of control/ supervision
• Thermodynamic cycle
optimization
Design
• Complete in-house
mechanical design
• Proprietary design
and own
manufacturing of
ORC optimized
turbine
• Tools
-
Thermo-fluiddynamic programs
-
FEA
-
3D CAD-CAM
-
Vibration analysis
Operations &
manufacturing
• Outsourced
components from
highly qualified
suppliers
• Quality assurance &
project management
• In house skid
mounting to
minimize site
activities
Commissioning and
Aftermarket
• Start-up and
commissioning
• Maintenance,
technical assistance
to operation and
spare parts service
• Remote monitoring
& optimization of
plant operation
software
• Many patents obtained
92
Project Schedule (typical)
93
ORC Operation and Maintenance – Operational logs +
remote monitoring
Several operational data are made
available to the Customer operation
team.
The signals exchanged between the
ORC and the operation team
control station can be defined
according to the specific requests.
94
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
geotermia
start-up
Plan
Riferimenti
95
Capex
96
Cash Flow Example: Italian «impianto pilota»
Framework: Italy, Feed-in Tariff (230 €/MWh)
Resource Conditions: T water = 140 °C, Flow rate = 220 kg/s
Powerplant performance: 8,5 MW gross, 5 MW net (Including all ORC aux. +
geothermal pumps)
Hypothesis: 4 wells 1200 m deep each, ESP required
Economical results:
Total Investment, including 1 ORC + Cooling System, BoP, Civil Works, Wells and
ESP = 34,1 M€
Expected O&M for the entire PP = about 700 k€/year
Resulting IRR @ 10 yrs = 15,6%
97
Business plan example I
Date:
Customer:
Geothermal site:
10/05/2015
n.d.
n.d.
Assumptions on geothermal field:
A) 4 production wells and 3 reinjection wells
B) Geothermal water temperature °C:
1. Geothermal Field (Capex)
No. Production wells
Production wells depth
No. Reinjection wells
Reinjection wells depth
Wells drilling cost
LEGENDA
input
calculation
140
Notes
4 wells
1200 m
3 wells
2600 m
1000 €/m
Total investment for drilling
No. geothermal Pumps
12.600.000
€
4 pumps
geothermal Pump cost
500.000
€/pump assumption
Total investment for pumps
2.000.000
€
Turboden ORC Scope
13.500.000
€
BoP + Piping + Electric + Civil
6.000.000
Total investment for surface plant
19.500.000
€
Total CAPEX
34.100.000
€
only for production wells (assumption
assumption
4012
98
Business plan example II
Expected drilling Time
Month
0 month
Month
Time of Order for ORC
Delivery Time of ORC
6 month
6 month
18 month
Time of ORC start up
3. Revenues and OPEX
Gross power Turboden ORC
Net power generation
Operating time
Energy Produced
Remuneration (F.I.T.)
Revenues
OPEX as a % of CAPEX
OPEX
discounting rate
24
start drilling of 1st production well
finishing of 1st production & reinjection well and successfull
circulation test
assumption: ORC is ordered soon after first 2 wells completed
from order to first start-up
month
8,50 MW
5,06 MW
8059 h/yr
40751 MWh
230 €/MWh
9.372.643 €/yr
2%
682.000
Net = Gross - (ORC + Geothermal pumps auxiliaries)
assuming total availablity per year
assuming that energy = design power output x operating hours
on net power
assumption based on similar geo projects
721.250 (OK, considering 20 USD/MWh)
7%
99
Business Plan example III
PBT
PBT (simple)
IRR (10 yrs)
IRR (15 yrs)
IRR (20 yrs)
IRR (25 yrs)
7,03 yrs
3,9
yrs
15,6%
19,9%
21,1%
21,5%
60,0
50,0
40,0
30,0
20,0
DCF
10,0
NPV
0
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
-10,0
-20,0
-30,0
-40,0
100
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
geotermia
start-up
Plan
Riferimenti
101
Geothermal markets I
102
Geothermal markets II
103
104
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
geotermia
start-up
Plan
Riferimenti
105
References
CONTACTS:
Joseph Bonafin – Sales Manager Geothermal: [email protected]
WEBSITES:
Turboden: http://www.turboden.eu/it/home/index.php ;
Unione Geotermica Italiana: http://www.unionegeotermica.it/
European Geothermal Energy Council: http://www.egec.org/
Geothermal Energy Association: http://www.geo-energy.org/
NEWSLETTERS:
http://thinkgeoenergy.com/
BOOKS:
Geothermal Power Plants Principles Applications Case Studies and Environmental Impact – Ronald
DiPippo
PAPERS:
https://pangea.stanford.edu/ERE/db/IGAstandard/search.php
106
Grazie per la vostra attenzione!
Joseph Bonafin – Sales Manager Geothermal
[email protected]
Back up
108
Geothermal Drilling Statistics
Approximately 2,218 well were drilled by 42 countries during the period
2010-2014 for both direct-use and electric power.
Shallow heat pump wells are not included in these figures.
In terms of the types of wells,
48.8% were drilled for power generation,
38.7% drilled for direct utilization,
8.6% drilled as combined heat and power wells,
3.9% drilled as research or gradient wells.
The total depth drilled by the 42 countries was 9,534.5 km for an average
of 4.30 km per well (over four times the depth drilled per well in 20052009).
The countries drilling more than 100 km during this period were: Hungary,
China, Kenya, Turkey, United States, Mexico,
Philippines and New Zealand (in descending order).
109
Drilling equipment
110
Geothermal Well
111
Heat recovery and biomass cycles: comparison of T-s
diagrams
112
Efficiency is a function of temperature 1/2
EFFICIENCY
TYPE
HEAT CARRIER
HEAT RELEASE
24%
Biomass
Combustion / CSP
Thermal oil
310°C (590°F)
Water
25°C (80°F)
Several ORC units under construction,
e.g. C&T 1,000 kW from biomass combustion (Ancona, Italy)
19%
Biomass
Combustion (CHP)
Thermal oil
310°C (590°F)
Water
75°C (170°F)
Over 50 installations
e.g. 3 x 1.5 MW from biomass combustion (Leoben, Austria)
19%
Heat
Recovery
Thermal oil
280°C (535°F)
Water
25°C (80°F)
~10 different ORC units,
e.g. 500 kW from MAN Diesel engine exhaust (Pavia, Italy)
Efficiency is a function of temperature 2/2
EFFICIENCY
TYPE
HEAT CARRIER
HEAT RELEASE
16%
Hot water
Heat Recovery
Water
180°C (355°F)
Water
30°C (86°F)
3 MW heat recovery ORC
for incinerator plant (Roeselare, Belgium)
8%-17%
Geothermal
Water
105°- 180 °C
(220°F)
Water
10°C (50°F)
1,000 kW geothermal ORC (Altheim, Austria)
7.5%
Jacket cooling Heat
Recovery
Water
95°C (200°F)
Air
15°C (60°F)
2.5 MW heat recovery ORC from
jacket water 6 x 17 MW Wartsila engines - study (Bari, Italy)
ORC Working Fluids
Silicone based
• Biomass
• Moderate & high temperature HR (e.g. gas turbine
exhaust, process waste gas)
• Concentrated solar power
Hydrocarbons
• Low cost, but highly flammable
• Low/moderate temperature HR
• Geothermal
Factors involved:
• Environment
• Safety
Fluorinated
• Cost
• Geothermal
• Low temperature HR (e.g. engine jacket
water, process hot water)
SOURCE TEMPERATURE
Inputs to be considered: well productivity
curve
Average flowing enthalpy: 750 kJ/kg
CO2 content: 3,6% in mass (calculated on total well flow)
116
ORC on island mode
Normal Operation
Electrical fault
on the grid
Island Mode
Electrical grid
restored
Normal Operation
In case of electrical fault on the grid outside the main
circuit, can be required to keep the ORC operating on island
mode (feeding the local auxiliaries).
Main advantages of this capability are:
• avoid start and stop of the geothermal pump, involving
less stress to the pumps and wells
• Keep the plant ready for quick re-synchro to the grid
• Increase availability of the district heating
The main issue of this process is related to the switch on and
off on the island operating mode, since it is required both fine
and fast regulation.
Sauerlach geothermal plant is designed to automatically
switch from normal operation to island operation.
During the island operation the power generated by the
turbines (P turbine) has to be equal to the power required
by the electrical loads of the plant (P island).
117
ORC on Island mode – Field tests Results
During the island operation the power generated by the
turbines (P turbine) has to be equal to the power required
by the electrical loads of the plant (P island).
The adopted solution allows to keep the frequency oscillation
within strict limits (<4%)
118

S - diegm

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