STEAM & POWER

ORC COGENERATION SYSTEM

FOR YOUR MANUFACTURING PROCESS.
High-temperature
ORC cogeneration system
Steam & Power ORC (Organic Rankine Cycle) System is a new technical solution for the cogeneration of high-temperature heat
and electricity (CHP), with a very high overall energy efficiency, directly employed in manufacturing and industrial processes.

 Electric power rating from 400 kWe to 10 MWe (multiple units)

 CHP steam output pressure range from 5 to 30 bar
 CHP steam capacity range from 4 to 80 t/h (multiple units)

AT YOUR SERVICE
Steam & Power ORC System was conceived to satisfy many manufacturing processes requiring electricity as well as relevant
amount of medium pressure steam.

FOOD & BEVERAGE CHEMICAL & PHARMACEUTICAL PAPER & WOOD INDUSTRY

TEXTILE PLASTIC & RUBBER OIL & GAS

Why choose Steam & Power
ORC System for energy efficiency?
HIGH STEAM PRODUCTION (NO LOW-TEMPERATURE HEAT)

VERY HIGH OVERALL EFFICIENCY (UP TO 94% WITH NATURAL GAS COMBUSTION)

HIGH FLEXIBILITY & DIFFERENT FUEL SOURCES

POSSIBILITY OF COMBINING THE SYSTEM WITH OTHER COGENERATION TECHNOLOGIES

HIGH EFFICIENCY AT PARTIAL LOAD DOWN TO 20%

LOW OPERATION AND MAINTENANCE COSTS

Which CHP scheme?
TOPPING CHP BOTTOMING CHP

FUEL COMBUSTION HEAT RECOVERY

 Natural Gas  Gas turbines
 Poor gases and by-products  Industrial processes
 Wood biomass, pellet
 Waste (sludge, residues etc.)

STEAM & POWER PRODUCTION

NOTE
Multiple heat sources can feed a single Turboden Steam & Power ORC System.
ORC working principle
ELECTRIC POWER

PROCESS
HEAT SOURCE* SELF-CONSUMPTION

GRID
STEAM

PROCESS
SELF-CONSUMPTION

(FEED WATER)

* ORC units can produce electric and/or mechanical power

The ORC turbogenerator makes use of a closed thermodynamic cycle to convert heat into electricity. The thermal power
recovered from the heat source vaporizes a suitable organic working fluid, which then expands through the turbine and
produces clean and reliable electric power through the alternator. Thanks to the regenerator, internal heat recovery takes place
improving the cycle efficiency. Downstream from the regenerator, the organic vapour is condensed and pumped back to start
the cycle again. The heat from condensation is used for steam production for manufacturing processes.

The heat input is transferred to the ORC working fluid by means of an intermediate circuit or directly via the combustion gases
in direct exchange system.

* Multiple heat sources can feed a single Turboden Steam & Power ORC System.
Steam & Power and circular economy
Turboden Steam & Power ORC Systems can be fed by multiple heat sources, offering an opportunity of exploiting by-products
of the manufacturing facility to further reduce natural gas consumption, CO2 emissions, and avoid disposal costs.
The residual wastes are thermovalorized and the resulting heat is converted into useful electricity & steam by Turboden
Steam & Power ORC System. If needed, the complementary heat required can be provided by natural gas. Thus, waste that used
to be a cost (for disposal) turns into a valuable asset (fuel).

STEAM & POWER

PROCESS BY-PRODUCTS

INDUSTRIAL PROCESS
Topping CHP: natural gas
Steam & Power ORC System, along with a gas-fired thermal oil boiler, can produce electricity and steam, directly exploitable in
manufacturing processes.
The innovative principle of Steam & Power ORC Systems is the temperature level of the cycle itself, about 100°C higher than for
standard ORC units. It allows cogeneration of electricity and steam at medium pressure with a very high overall energy efficiency.

STEAM* 76%

ELECTRICITY 16%

LOSSES 8%

Example of a topping natural gas-fired configuration with a Turboden Steam & Power ORC System.

* Steam output at 10 bar(g)

Technology benchmark
and comparison
Combined Heat and Power (CHP) systems are universally acknowledged as a profitable, efficient, and sustainable way of
generating energy for manufacturing industries.
Turboden Steam & Power ORC System is the best solution for cogeneration of medium pressure steam and electricity, ideal for industrial
processes with a steam capacity from 3 to 80 t/h (multiple units) and an electricity demand between 400 kW and 10 MW (multiple units).

TURBODEN POSITIONING IN THE CHP MARKET

2
Electricity to steam ratio

ICE
1
MGT
0.5 GT
Legend:
ICE = Internal Combustion Engine 0.2 ST&P
GT = Gas Turbine
MGT = Micro Gas Turbine 0.1 ST
ST = Steam Turbine
ST&P = Steam & Power ORC
0.1 0.3 1 3 10 30
Electricity output [MWe]

TURBODEN STEAM & POWER: A NEW COGENERATION TECHNOLOGY

traditional system combined steam & power systems

8% LO 8% LO 8% LO
22% LO
38% LO 16% EE 8% EE

28% EE

92% ST 44% EE 84% ST

76% ST
50% ST
18% ST

STEAM boiler I.C. engine GAS turbine ST&P ORC STEAM turbine
NOTES
1. Turboden elaboration of major OEM datasheets.
2. Jacket water heat for I.C. engine is accounted as losses. Legend: LO = losses EE = electricity ST = steam
Case history:
Steam & Power for a dairy
“Centrale del Latte is very sensitive to
clean and environmentally-friendly
solutions. High-efficiency cogeneration
fits in perfectly with our philosophy: for
some years we have been looking for a
suitable technology for our energy needs
and to improve the energy efficiency of
our production plant. We are sure that the
synergy between Turboden and our dairy,
two important companies in Brescia’s
industrial context, will certainly lead to a
successful project.”
Franco Dusina
President of Centrale del Latte di Brescia
THE CUSTOMER
Centrale del Latte di Brescia established in 1930 with the objective
of ensuring hygiene checks on milk and daily distribution to
all citizens. Centrale del Latte di Brescia was the first municipal
dairy in Italy to have a UHT plant for production of long-life milk.
The company was the first in the world to pack UHT milk in fully
recyclable PET bottles.
THE NEED
Centrale del Latte di Brescia used to produce steam by means of a
traditional boiler buying electric power from the local grid.
The customer decided to look at a cogeneration solution to increase
the overall efficiency of the system and reduce related costs.
OUR SOLUTION
Turboden provides a turnkey solution, supplying the complete
plant, from the direct exchange system between the primary heat
source and the ORC working fluid to the high-temperature ORC
turbogenerator. The Turboden solution perfectly fits the energy
needs of Centrale del Latte di Brescia, which uses an ST&P ORC
System to co-generate about 700 kW electric power and 5 ton/hour
of steam at 15 bar(a) needed to pasteurize long-life milk.
A typical business case
ST&P ORC SYSTEM TD 6
Steam capacity [t/h] 6

Electrical gross output [kW] 890

Electrical gross efficiency [%] * 16

Captive consumption [%] ** 7

CAPEX [€/kWe]*** 2,500

Maintenance cost [€/kWhe] 0.005

Electricity price [€/MWh] 100

PBT [years] 3

IRR [%] 30

HYPOTHESIS and NOTES

1. Differential analysis of CHP technology compared

to a conventional steam generation system (thermal only).
2. Existing boiler efficiency 90%.
3. Steam output at 15 bar(a).
4. Natural gas price 25 €/MWh.
5. Equivalent working hours 8,000 h/year.
6. Italian scenario considering Italian incentive regulation
for CAR (white certificates, tax regulations on electricity
and exemption of taxes for natural gas).
* Compared to fuel input.
** On gross electrical output.
*** Excluding civil and electrical connection.
Bottoming CHP:
revamping gas turbine
By adding Steam & Power ORC System as the bottoming cycle of a gas turbine, you can enhance the electrical output of the CHP
system maintaining a valuable steam output in CHP mode.

ST&P ORC System increases the power output of the gas turbine from +15-20%
Steam production in CHP is reduced by a 10-15% only
Enhancing power production gives benefits to power plant sustainability

Example of a bottoming Steam & Power ORC System recovering waste heat from a gas turbine or an industrial process.
Case study:
Steam & Power for a chemical industry

THE CUSTOMER
The ideal customer is a leading European manufacturer
of a wide range synthetic fibres.

THE NEED
The power plant requires about 6 MW electric power
and 11 ton/hour steam at 7 bar(a).
The plant is already equipped with an existing gas
turbine working in cogeneration with a bottoming
HRSG. Moreover, the plant needs to ensure the
possibility of island mode operation in order to ensure
production stability.

OUR SOLUTION
To improve energy efficiency, Turboden supplies an ORC
unit bottoming the existing gas turbine, generating an
additional 1000 kW, with a valuable steam output of
about 11 ton/hour.
By adding the Steam & Power ORC System, the overall
cogeneration plant electrical efficiency increases by 5.5%.
Technical & economical features
TOPPING GAS TURBINE
Electrical gross output [kW] 5,100

Electrical gross efficiency [%] 30.2

Exhaust mass flow [kg/s] 19.5

Exhaust temperature [°C] 545

BOTTOMING ST&P TD 8
8 from ORC +
Steam capacity [t/h]
3.1 from HR

Electrical gross output [kW] 900

Electrical gross efficiency [%] * 16

Captive consumption [%] ** 5

CAPEX[€/kWe]*** 3,000 HYPOTHESIS and NOTES

Maintenance cost [€/kWhe] 0.005 1. Differential analysis of combined cycle respect to GT + HRSG.
2. Revamping of an existing GT.
3. Steam output at 7 bar(a).
Electricity price [€/MWh] 90 4. Natural gas price 25 €/MWh.
5. Equivalent working hours 8,000 h/year.
6. Italian scenario considering Italian incentive regulation for
PBT [years] 3
CAR (white certificates and tax exemption for natural gas).
* Compared to thermal input to ORC.
IRR [%] 35 ** On gross electrical output.
*** Excluding civil and electrical connection.
ABOUT US
Turboden, a group company of Mitsubishi Heavy Industries, is an Italian firm and a global leader in the design, manufacture
and maintenance of Organic Rankine Cycle (ORC) systems, highly suitable for distributed power generation. ORC systems can
generate electric and thermal power exploiting multiple sources, such as renewables (biomass, geothermal energy, solar energy),
traditional fuels and waste heat from industrial processes, waste incinerators, engines or gas turbines.

Mitsubishi Heavy Industries, Ltd. (MHI), headquartered in Tokyo, is one of the world’s leading industrial firms with 80,000 group employees
and annual consolidated revenues of around 38 billion U.S. dollars (year 2018). For more than 130 years, the company has channeled big
thinking into innovative and integrated solutions that move the world forward. MHI owns a unique business portfolio covering land, sea,
sky and even space. MHI delivers innovative and integrated solutions across a wide range of industries from commercial aviation and
transportation to power plants and gas turbines, and from machinery and infrastructure to integrated defense and space systems.

Why Turboden?
PART OF MITSUBISHI CAPABILITIES CUSTOMER
HEAVY INDUSTRIES GROUP & EXPERIENCE ORIENTATION

Turboden benefits from the Mitsubishi
Heavy Industries global network in a
number of ways, including: financial
stability, sharing of business practices
(including customer warranties) and
technology development.
With over 35 years of experience, a
global presence, 600+ MWe installations,
and 390+ plants in 45 countries,
Turboden is a market leader in the
proprietary design and manufacturing
of ORC optimized turbines.
Optimized solutions for each
customer and a qualified service
department exclusively dedicated to
customer assistance.
Feel our strengths
Range size up to 20 MW per single shaft
Different primary energy sources
Large rangeability
Cogeneration or power-only mode

FLEXIBILITY
Ease of integration

*
Island mode

High availability (98%+)

Long life

* *
TURBODEN
RELIABILITY
ORC SUSTAINABILITY

Core system for renewable

energy and energy efficiency

*
Simple technical features: low pressures Clean generation of power
involved, low speed turbine, limited and heat
number of stages of the turbine (≤6), Reduction of CO² emissions

EASY
self-lubricating fluids, no water required
Easy and cost-effective operation &
maintenance: automatic operation (no TECHNOLOGY
qualified operator required), minimal
maintenance activities, no major
overhaul (turbine not subject to erosion
or corrosion), fast start-stop procedures,
no chemical and water treatments, low
refilling of fluid required
Always by your side
24/7
SUPPORT*
<2h
REACTION TIME
97%
PLANTS WITH AFTER-SALES
CONTRACTS

*up to

GLOBAL COVERAGE
2 service subsidiaries and 5 international service partner companies

CUSTOMIZED SERVICES
single contact for requests for support
staff dedicated to on-site and remote technical support
assistance of an international network of companies able to provide technical support
wide range of services provided
prompt assistance and customized after-sales services
remote technical support using innovative tools
dedicated spare parts warehouse

CUSTOMER REQUEST TREND ANALYSIS FOCUSED TEAMWORK REACTION PLAN: SATISFIED

OR TURBODEN WITH LOCAL AND TECHNICAL REMOTE OR ON-SITE CUSTOMER
PLANNED CHECKS OPERATOR SUPPORT DECISIONS
Meet our global
and proven experience

PLANTS: 391
COUNTRIES: 45
TOTAL CAPACITY: 661.3 MWe
CUMULATIVE OPERATION TIME: 17.5 million hours
AVERAGE AVAILABILITY: 98+% Update April 2020
 STEAM & POWER

Turboden S.p.A. | Via Cernaia, 10 | 25124 Brescia | Italy | Tel +39.030.3552001 | www.turboden.com 16-COM.B-1-rev.5