2019 WASTE HEAT RECOVERY 11-COM.P-18-rev.64 PDF

TURBODEN
WASTE HEAT
RECOVERY
Cod. 11-COM.P-18-rev.64
INCREASE YOUR ENERGY EFFICIENCY WITH ORC TECHNOLOGY.

WASTE HEAT RECOVERY APPLICATION
Turboden Organic Rankine Cycle (ORC) units can produce electricity by recovering residual low-grade heat
from industrial processes and from internal combustion engines, gas turbines, and fuel cells operating on
open cycle.
The generated power ranges up to 20 MW electric per single shaft.
Waste Heat Recovery Plants: 34

Total Capacity: 79.2 MWe
In Operation: 23
Under Construction: 11
2 Waste heat recovery

Copyright © – Turboden S.p.A. All rights reserved
ENERGY EFFICIENCY IN YOUR BUSINESS
Where to take action?
Unexploited
waste heat streams
converted into
PRODUCTION PROCESSES OPEN CYCLES
Unexploited heat streams Exhaust gases released by gas ELECTRIC POWER

produced by industrial processes turbines, internal combustion
like cement, glass, steel, ferroalloy, engines, and fuel cells operating on and/or
non-ferrous metals (copper, open cycle.
MECHANICAL POWER
aluminum, etc.), silicon metal,
carbon black, etc.

WHY CHOOSE ORC FOR ENERGY EFFICIENCY?
Generate profit from leveraging a waste heat source
Reduce specific production cost by decreasing energy demand

Improve energy-intensive industry sustainability
Reduce CO2 emissions

THE ORC CYCLE – HOW IT WORKS
The ORC turbogenerator uses
medium-to-high temperature
thermal oil to preheat and vaporize
a suitable organic working fluid in
the evaporator (4>5). MAIN HEAT SOURCE
The organic fluid vapor rotates the

turbine (5>6), which is directly
coupled to the electric generator,
resulting in clean, reliable electric
power.
The exhaust vapor flows through
the regenerator (6>7), where it
heats the organic liquid (2>3) and
is then condensed in the
condenser and cooled by the
cooling circuit (7>8>1).
The organic working fluid is then
pumped (1>2) into the regenerator
and evaporator, thus completing
the closed-cycle operation.
The waste heat from production process is transferred to the ORC working fluid by means of an intermediate
circuit or directly via the exhaust gases in direct exchange systems. The media used in the intermediate
circuits are thermal oil, saturated steam or superheated water.
TURBODEN REFERENCES IN CEMENT
APPLICATION TYPICAL GAS TEMPERATURES DUST

(MIN - MAX) °C (CONTENT AND AGGRESSION)
Cement 280 – 400 High
Glass 350 – 500 Medium
Glass oxyfuel 600 – 800 Medium
Steel – EAF 800 – 1000 High
Steel – BOF 800 – 1000 Medium
Steel – SAF 300 – 400 Medium - High
Steel – Rolling mill 300 – 400 Low – Medium
Steel – Sinter 300 – 400 Medium – High
Combined cycles 350 – 500 Low
Low-temperature sources 150 – 250 Low

THERMODYNAMIC CYCLE: ORC VS STEAM
STEAM RANKINE CYCLE ORGANIC RANKINE CYCLE
3’
Temperature
Temperature
3
3
2 4
2
1
1 4 4’
Entropy Entropy
 High enthalpy drop  Small enthalpy drop
Thermodynamic features  High pressures and temperatures  No supercritical pressure
and consequences  Superheating needed  No need to superheat
 Risk of blade erosion  No risk of blade erosion
 Water treatment required  Water-free system

Operation and maintenance
 Highly skilled personnel needed  Minimum personnel and Operation & Maintenance cost
costs
 Periodic major overhaul  No major overhaul
 Completely automatic
 Low flexibility with significantly lower performances at partial load  High flexibility - Wide operational range from 10% to 110%
Other features  High availability (average >98%)
 Convenience for large plants and high temperatures

COMPARISON WITH STEAM TECHNOLOGY
100%
50% PARTIAL LOAD
Actual efficiency / Nominal efficiency
90%
80%
70%
ORC 90%
60% STEAM 70%
50%
40%
30%
20% ORC
30% PARTIAL LOAD
10% STEAM
0%
ORC 80%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
STEAM 55%
Actual load / Nominal load
NOTE: steam turbine suffers partial load operation due to high risk of blade erosion.

WASTE HEAT RECOVERY IN CEMENT INDUSTRY
In cement production process,

Turboden ORC systems can produce
electric power by recovering waste
heat from two hot gas streams:
 kiln pre-heater (PH) gas
 clinker cooler (CC) gas
Turboden ORC systems are easy to

integrate, with no impact on
industrial process or prime
equipment (engine, gas turbine)
operation.

TURBODEN REFERENCES IN CEMENT
ORC GROSS
KILN CAPACITY
PLANT START UP COUNTRY HEAT SOURCE HEAT CARRIER ELECTRIC
(TON/DAY)
POWER (kW)
CIMENTS DU MAROC
(HeidelbergCement Group, 2010 Morocco 5,000 PH thermal oil 2,000
former Italcementi)
HOLCIM ROMANIA thermal oil +
2012 Romania 4,000 PH + CC 4,000
(LafargeHolcim Group) superheated water
CRH SLOVAKIA
2014 Slovakia 3,600 PH + CC thermal oil 5,000
(former Holcim Group)
CARPATCEMENT
2015 Romania 3,500 PH + CC thermal oil 3,800
(HeidelbergCement Group)
JURA-CEMENT-FABRIKEN
2016 Switzerland 3,000 PH superheated water 2,300
(CRH Group)
none – direct
CEMENTI ROSSI 2018 Italy 3,500 PH + CC 2,000
exchange
ÇİMKO
(Sanko Group) 2019 Turkey 7,500 CC thermal oil 7,000
EPC: CTP Team
HOLCIM SUISSE ECLÉPENS under
Switzerland 2,300 PH + CC thermal oil 1,300
(LafargeHolcim Group) construction
SÖNMEZ ÇIMENTO under
Turkey 6,000 PH + CC thermal oil 7,300
EPC: CTP Team construction
CIMENTS DU MAROC
CUSTOMER:
Ciments du Maroc (HeidelbergCement Group - former Italcementi)
COUNTRY:
Morocco
CLINKER PRODUCTION CAPACITY:
≈ 5,000 ton/day
STATUS:
in operation since November 2010
ORC SIZE:
2 MW
HEAT SOURCE:
pre-heater exhaust gas + concentrated solar power (CSP) collectors
HEAT CARRIER:
thermal oil
COOLING SYSTEM:
water cooled condenser + air cooler (no water consumption)

HOLCIM ROMANIA
CUSTOMER:
Holcim Romania (LafargeHolcim Group)
COUNTRY:
Romania
≈ 4,000 ton/day
STATUS:
in operation since July 2012
ORC SIZE:
4 MW
HEAT SOURCE:
pre-heater exhaust gas + clinker cooler air
HEAT CARRIER:
thermal oil + superheated water
COOLING SYSTEM:
water cooled condenser + cooling towers (open loop)

CRH
CUSTOMER:
CRH (former Holcim Group)
COUNTRY:
Slovakia
≈ 3,600 ton/day
STATUS:
in operation since February 2014
ORC SIZE:
5 MW
HEAT SOURCE:
HEAT CARRIER:
thermal oil
COOLING SYSTEM:

CARPATCEMENT
CUSTOMER:
Carpatcement (HeidelbergCement Group)
COUNTRY:
Romania
≈ 3,500 ton/day
STATUS:
in operation since July 2015
ORC SIZE:
3.8 MW
HEAT SOURCE:
HEAT CARRIER:
thermal oil
COOLING SYSTEM:
air cooled condenser (no water consumption)

JURA-CEMENT-FABRIKEN
CUSTOMER:
Jura-Cement-Fabriken (CRH Group)
COUNTRY:
Switzerland
≈ 3,000 ton/day
STATUS:
ORC SIZE:
2.3 MW
HEAT SOURCE:
pre-heater exhaust gas
HEAT CARRIER:
superheated water
COOLING SYSTEM:

DIRECT EXCHANGE FROM CC HOT GAS
STREAM
Direct heat Air

ORC working recovery cooling
fluid Stack
exchanger system
Filter
Raw mill
Electric
power ORC unit
Stack
Filter
Cooling system
Rotary kiln
Clinker cooler
CEMENTI ROSSI
CUSTOMER:
Industria Cementi Giovanni Rossi
COUNTRY:
Italy
≈ 3,500 ton/day
STATUS:
under commissioning
ORC SIZE:
2 MW
HEAT SOURCE:
pre-heater exhaust gas + clinker cooler air mixed
HEAT CARRIER:
not present, direct exchange
COOLING SYSTEM:

ÇIMKO
CUSTOMER:
CTP Team / Çimko (Sanko Holding)
COUNTRY:
Turkey
≈ 7,500 ton/day
STATUS:
in operation since June 2019
ORC SIZE:
7 MW
HEAT SOURCE:
clinker cooler air
HEAT CARRIER:
thermal oil
COOLING SYSTEM:

HOLCIM SUISSE ECLÉPENS
CUSTOMER:
Holcim Suisse Eclépens (LafargeHolcim Group)
COUNTRY:
Switzerland
2,300 ton/day
STATUS:
under construction
ORC SIZE:
1.3 MW
HEAT SOURCE:
HEAT CARRIER:
thermal oil
COOLING SYSTEM:
water cooled condenser + air cooler (no water consumption)

SÖNMEZ ÇIMENTO
CUSTOMER:
CTP Team / Sönmez Çimento
COUNTRY:
Turkey
≈ 6,000 ton/day
STATUS:
under construction
ORC SIZE:
7.3 MW
HEAT SOURCE:
HEAT CARRIER:
thermal oil
COOLING SYSTEM:

HEAT RECOVERY IN STEEL AND METALS
MAIN EXHAUST GAS STREAMS
 Rolling, forging  Blast oxygen furnaces

 Strip processing  Sinter
 Heat treatment  Coke ovens
 Annealing  Electric Arc Furnace
 Submerged Arc Furnace
Exhaust gas: relatively clean at Exhaust gas: high flows at high

moderate temperature temperatures, high dust
content, large variations in
operating cycle (EAF)

TURBODEN REFERENCES IN STEEL & METAL
PLANT START UP MAIN PROCESS EQUIPMENT HEAT CARRIER ORC
type charge capacity gross electric power (kW)

NATSTEEL steel none – direct
2013 billet 125 ton/h 700
Singapore rolling mill billet reheating furnace exchange
ELBE STAHLWERKE FERALPI steel
2013 scrap 100 ton saturated steam 2,700
Germany electric arc furnace
ORI MARTIN steel
2016 scrap - consteel 85 ton saturated steam 2,200
Italy electric arc furnace
FONDERIA DI TORBOLE iron
2016 scrap, pigs 30 ton/h thermal oil 700
Italy cupola furnace
AICHI STEEL under steel
scrap 100 ton saturated steam 2,500
Japan construction electric arc furnace
ARVEDI steel
2018 scrap 250 ton saturated steam 10,000
Italy electric arc furnace
SAFRAN
under chemical vapor infilatration
EPC: INVEST ENERGY n.a. n.a. thermal oil 1,900
construction furnace
Malaysia
POSCO ICT under Fe-Mn
raw materials 150 ton/d thermal oil 1,200
South Korea construction submerged arc furnace
SACAL under aluminum
22Italy Waste heat recovery scrap n.a. thermal oil 2,100
construction rotative furnaces
ESF ELBE-STAHLWERKE FERALPI
CUSTOMER:
ESF Elbe-Stahlwerke Feralpi GmbH
COUNTRY:
Germany
TYPE OF PROCESS FOR WHR:
steel - electric arc furnace
STATUS:
in operation since December 2013
ORC SIZE:
2.7 MW
HEAT SOURCE:
EAF exhaust gas
HEAT CARRIER:
saturated steam
COOLING SYSTEM:

FONDERIA DI TORBOLE
CUSTOMER:
Fonderia di Torbole
COUNTRY:
Italy
iron cupola furnace
STATUS:
ORC SIZE:
0.7 MW
HEAT SOURCE:
cupola furnace exhaust gas
HEAT CARRIER:
thermal oil
COOLING SYSTEM:
water cooled condenser + air coolers (no water consumption)

ARVEDI
CUSTOMER:
Arvedi S.p.A.
COUNTRY:
Italy
STATUS:
in operation since January 2018
ORC SIZE:
10 MW
HEAT SOURCE:
EAF exhaust gas
HEAT CARRIER:
saturated steam
COOLING SYSTEM:

ORI MARTIN
CUSTOMER:
ORI Martin
COUNTRY:
Italy
STATUS:
in operation since March 2016
ORC SIZE:
2.2 MW
HEAT SOURCE:
EAF exhaust gas
HEAT CARRIER:
saturated steam
COOLING SYSTEM:

HEAT RECOVERY IN GLASS INDUSTRY
HEAT SOURCES MAIN PROPERTIES
High-temperature ORC
 Constant operating conditions
cycle employed with
 Exhaust gas with moderate dust content
electrical efficiency
 High exhaust gas temperature
up to 26%
 Exhaust gas must be cooled not below 180-200°C

TURBODEN REFERENCES IN GLASS INDUSTRY
PLANT COUNTRY START UP MAIN PROCESS EQUIPMENT HEAT CARRIER ORC
type capacity gross electric power (kW)

AGC
Italy 2012 float glass 600 ton/d thermal oil 1,300
(GEA Bishoff)
UNDISCLOSED Italy 2015 container glass 500 ton/d thermal oil 500
DÜZCE CAM
Turkey 2018 float glass 2 x 600 ton/d thermal oil 6,200
(Çalbıyık Grup)
SAINT-GOBAIN under
India float glass 600 ton/d thermal oil 1,200
(GEA Bishoff) construction
1,200
SAINT-GOBAIN under
Italy float glass 600 ton/d thermal oil (mechanical power used to
(GEA Process Engineering) construction
produce compressed air)

AGC
EPC / FINAL USER:
GEA Bischoff / AGC Flat Glass Italia
COUNTRY:
Italy
GLASS PRODUCTION CAPACITY:
600 ton/day
STATUS:
in operation since February 2012
ORC SIZE:
1.3 MW
HEAT SOURCE:
float glass furnace exhaust gas
HEAT CARRIER:
thermal oil
COOLING SYSTEM:
water cooled condenser + cooling towers

GLASS PRODUCER
EPC / FINAL USER:
undisclosed
COUNTRY:
Italy
500 ton/day
STATUS:
in operation since May 2015
ORC SIZE:
0.5 MW
HEAT SOURCE:
container glass furnace exhaust gas
HEAT CARRIER:
thermal oil
COOLING SYSTEM:
water cooled condenser + closed loop cooling towers

DÜZCE CAM
EPC / FINAL USER:
Calbıyık Grup / Düzce Cam
COUNTRY:
Turkey
2 x 600 ton/day
STATUS:
in operation since September 2018
ORC SIZE:
6.2 MW
HEAT SOURCE:
two float glass furnaces exhaust gas
HEAT CARRIER:
thermal oil
COOLING SYSTEM:

SAINT GOBAIN ITALY
EPC / FINAL USER:
GEA Process engineering / Saint Gobain Italy
COUNTRY:
Italy
WASTE 600 ton/day
HEAT
GLASS PRODUCTION STATUS:
HEAT
PROCESS
EXCHANGER
ELECTRIC POWER under construction
ORC SIZE:
~ 1 MW
COMPRESSED AIR SOLUTION:
ORC TURBINE TO THE PROCESS ORC turbine connected to double-shaft generator
and air compressor
COMPRESSOR
COMPRESSED AIR PRODUCTION:
84 Nm3/min at 7 Bar(g)
REGENERATOR
HEAT SOURCE:
float glass furnace exhaust gas
HEAT CARRIER:
thermal oil
CONDENSER
COOLING SYSTEM:
32 Waste heat recovery water cooled condenser + closed loop cooling towers
OVERALL PLANT PERFORMANCES
GAS TURBINES 30÷40% ORC additional power*
GT USEFUL POWER 18 ÷ 30% Useful power ***
80 ÷ 68% Thermal power

EXHAUST GAS**
2% Thermal losses
ORC unit
INTERNAL COMBUSTION ENGINES 10% ORC additional power*

2% Thermal losses
80 ÷ 72% Thermal power

EXHAUST GAS**
ORC unit 18 ÷ 26% Useful power ***
ICE USEFUL POWER
JACKET WATER
* ORC power output compared to GT or ICE shaft capacity
(e.g. 10 MW GT  3÷4 MWe ORC; 10 MW ICE  approx. 1 MWe ORC).
** Min. flow to ORC: from GT 10-15 kg/s; from ICE 30-40 kg/s.
33 Waste heat recovery *** Mechanical and/or electric, calculated on thermal power input to ORC.

GAS TURBINE BOTTOMING WITH ORC
• Special ORC unit, developed with
gas turbine OEM
NOTES:
 Indicative values assuming gas turbines operating at nominal
load with exhaust gas properties as reported in specific suppliers
websites.
 Shaded area represents the potential ORC power output in
relation to gas turbine(s) shaft power. ORC performance may
vary depending on specific project features.

INTERNAL COMBUSTION ENGINES
BOTTOMING WITH ORC
18
9 x MAN 51/60G
16
14
ORC power output [MW]
6 x MAN 51/60G 8 x Wartsila 18V50

12
10
6 x Wartsila 18V50
8
3 x MAN 51/60G
6
NOTES:
4 3 x Wartsila 18V32 3 x Wartsila 18V50  Indicative values assuming ICE operating at nominal load
with exhaust gas properties as reported in specific
1 x Wartsila 18V50
8 x Jenbacher JMS624
suppliers websites.
2  Shaded area represents the potential ORC power output in
3 x Wartsila 12V32 relation to engine(s) nominal power. ORC performance
may vary depending on specific project features.
0
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
4 x Jenbacher JMS624
ICE ISO rated power [MW]

TRANSGAS
CUSTOMER:
TransGas
COUNTRY:
Canada
STATUS:
ORC SIZE:
1 MW
HEAT SOURCE:
exhaust gas of a 3.5 MW Solar Centaur 40 gas turbine in a gas
compressor station along TransGas pipeline
HEAT CARRIER:
thermal oil
COOLING SYSTEM:
water cooled condenser + air coolers (closed water loop)

UZTRANSGAZ
CUSTOMER:
Uztransgaz
COUNTRY:
Uzbekistan
STATUS:
under construction
ORC SIZE:
1 MW
HEAT SOURCE:
exhaust gas of a 3 x 15 MW GE gas turbines in the gas compressor
station serving the Hodzhaabad Underground Storage System
HEAT CARRIER:
thermal oil
COOLING SYSTEM:

UZTRANSGAZ
FEATURES
 Fully containerized unit,

suitable for climatic and
seismic conditions of
Uzbekistan.
 Minimization of on-site
activities with consequent
reduction of EPC costs.
 Optimization of operation
& maintenance activities –
possibility to use existing
personnel of customer.

UZNEFTEGAZDOBYCHA
CUSTOMER:
Uzneftegazdobycha
COUNTRY:
Uzbekistan
STATUS:
under construction
ORC SIZE:
5.5 MW
HEAT SOURCE:
exhaust gas of a 23 MW GE LM 2500 gas turbine in the gas
compressor station serving Shurtan Gas Chemical Complex
HEAT CARRIER:
not present – direct exchange
COOLING SYSTEM:

LUKOIL
CUSTOMER:
LUKoil
COUNTRY:
Russia
STATUS:
in operation since September 2015
ORC SIZE:
1.8 MW
HEAT SOURCE:
flare gas in LUKoil refinery
HEAT CARRIER:
thermal oil
COOLING SYSTEM:
water cooled condenser in CHP mode - hot water exploited for oil
pumping

TURBODEN REFERENCES FROM ENGINES
PLANT COUNTRY START UP ORC SIZE (MWe) ENGINES
PISTICCI I Italy 2010 1.8 3 x 8 MWe Wärtsilä diesel engines

TERMOINDUSTRIALE Italy 2008 0.5 1 x 8 MWe MAN diesel engine
PISTICCI II Italy 2012 4 2 x 17 MWe Wärtsilä diesel engines
CEREAL DOCKS Italy 2012 0.5 (direct exchange) 1 x 7 MWe Wärtsilä diesel engine
2 x 1 MWe Jenbacher gas engines + 3 x 0.8 MWe Jenbacher gas
E&S ENERGY Italy 2010 0.6
engines + 1 x 0.6 MWe Jenbacher gas engine – landfill gas
ULM Germany 2012 0.7 2 x 2 MW Jenbacher gas engines (+ additional heat from process)
KEMPEN Germany 2012 0.6 Gas engines
MONDO POWER Italy 2012 1 1 x 17 MWe Wärtsilä diesel engine
HSY Finland 2011 1.3 4 x 4 MWe MWM gas engines – landfill gas
FATER Italy 2013 0.7 (direct exchange) 1 x 8 MWe Wärtsilä diesel engine
28 x 1.4 MWe Jenbacher engines + 4 x 1.2 MWe MWM engines –
ORTADOGU I Turkey under construction 2 x 2.3
landfill gas
ORTADOGU II Turkey under construction 2.3 12 x 1.4 MWe Jenbacher engines – landfill gas
BIOGASTECH Belgium under construction 0.7 4 x 3.3 MWe Jenbacher gas engines


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TURBODEN

INCREASE YOUR ENERGY EFFICIENCY WITH ORC TECHNOLOGY.

Waste Heat Recovery Plants: 34

2 Waste heat recovery

PRODUCTION PROCESSES OPEN CYCLES

Unexploited heat streams Exhaust gases released by gas ELECTRIC POWER

3 Waste heat recovery

Reduce specific production cost by decreasing energy demand

Reduce CO2 emissions

4 Waste heat recovery

The organic fluid vapor rotates the

APPLICATION TYPICAL GAS TEMPERATURES DUST

Cement 280 – 400 High

Glass 350 – 500 Medium

Glass oxyfuel 600 – 800 Medium

Steel – EAF 800 – 1000 High

Steel – BOF 800 – 1000 Medium

Steel – SAF 300 – 400 Medium - High

Steel – Rolling mill 300 – 400 Low – Medium

Steel – Sinter 300 – 400 Medium – High

Combined cycles 350 – 500 Low

Low-temperature sources 150 – 250 Low

6 Waste heat recovery

 Water treatment required  Water-free system

7 Waste heat recovery

8 Waste heat recovery

In cement production process,

Turboden ORC systems are easy to

9 Waste heat recovery

11 Waste heat recovery

12 Waste heat recovery

13 Waste heat recovery

14 Waste heat recovery

15 Waste heat recovery

Direct heat Air

17 Waste heat recovery

18 Waste heat recovery

19 Waste heat recovery

20 Waste heat recovery

MAIN EXHAUST GAS STREAMS

 Rolling, forging  Blast oxygen furnaces

Exhaust gas: relatively clean at Exhaust gas: high flows at high

21 Waste heat recovery

type charge capacity gross electric power (kW)

23 Waste heat recovery

24 Waste heat recovery

25 Waste heat recovery

26 Waste heat recovery

HEAT SOURCES MAIN PROPERTIES

27 Waste heat recovery

type capacity gross electric power (kW)

28 Waste heat recovery

29 Waste heat recovery

30 Waste heat recovery

31 Waste heat recovery

80 ÷ 68% Thermal power

INTERNAL COMBUSTION ENGINES 10% ORC additional power*

80 ÷ 72% Thermal power