Tags Posts tagged with "heat recovery"

heat recovery

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E.ON, DeltaPort and the aluminium producer TRIMET have presented the “EcoPort 813” project. The partners are planning to convert heat from the production of aluminium into a resource-saving energy source in order to supply logistics properties at the Rhine port of Voerde-Emmelsum. The low-cost and CO2-neutral energy in the form of heat or cold is intended to create incentives for the settlement of further companies.

In addition, the partners want to make the logistics chain for food climate-friendly. Usually, temperature-controlled containers that land in the seaport by sea-going ship are unloaded in refrigeration centres and then transported on the road to the hinterland.

“EcoPort 813” aims to optimize this supply chain ecologically. In the future, refrigerated containers will be transported to the hinterland by inland waterway or rail. The containers can be unloaded at a temperature-controlled distribution centre in the port of Emmelsum, from where they can be distributed by truck. The truck will thus only be used on the last mile.

E.ON will contribute the hub of the project: an energy centre with heat recovery. The excess heat from TRIMET’s aluminium production is recycled here. Converted into cold, it can be made available to cooling logistics companies, but also in the form of heat for the manufacturing industry. The companies receive cold or heat at uniquely low energy costs without polluting the climate with CO2. The plant generates up to 136 GWh of usable heat per year. More than 27,000 t of CO2 can be saved. At the beginning of the year, E.ON initiated a similar project in the port of Dortmund.

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The new Cap des Biches power plant was inaugurated in Senegal on 13 June. The 53 MW Flexicycle plant comprises three Wärtsilä 46 internal combustion engines and a combined cycle heat recovery system. The ceremony was hosted by the owner of the plant, ContourGlobal, and the official inauguration of the plant was performed by the President of Senegal, Mr. Macky Sall.

“The Cap des Biches power plant proceeded from concept to the live generation of electricity in just 14 months – twice as fast as similar projects. ”

The power plant will feed electricity to the national grid under a 20 year power purchase agreement (PPA) between ContourGlobal and Senelec, the national electricity company of Senegal. The project is financed by International Finance Corporation (IFC), a subsidiary of the World Bank Group, and the Overseas Private Investment Corporation (OPIC). The project is part of the U.S. Government’s Power for Africa initiative, which aims to add 30 000 MW of new power generation capacity in Sub-Saharan Africa.

Wärtsilä and ContourGlobal have already signed a contract to expand the power plant with two additional Wärtsilä 46 engines having a combined capacity of 34 MW. Once completed, the 87 MW power plant will provide a 10 percent increase to Senegal’s current total generation capacity of 860 MW, making it critical covering the growing electricity demand in Senegal. The parties have also signed a five-year maintenance and spare part agreement.

The project is designed so that the plant can quickly be converted to natural gas as soon as it becomes available. Senelec has announced plans to invest in a floating liquefied natural gas (LNG) regasification terminal. This will improve Senegal’s fuel security, reduce carbon emissions, and lower the cost of electricity to the consumer.

With the Cap des Biches extension project completed, Wärtsilä’s installed capacity in Senegal will reach 465 MW, some 55 percent of the country’s total capacity. In all of Africa, Wärtsilä has delivered approximately 6500 MW of power plant capacity in 46 countries. Globally, Wärtsilä’s installed base is 58 GW in 175 countries.


Source: Wärtsilä

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Turboden, a group company of Mitsubishi Heavy Industries (MHI), leader in Organic Rankine Cycle (ORC) turbogenerators for distributed power generation employing renewable sources and waste heat, signed an order with Acciaieria Arvedi for a new waste heat recovery ORC unit to be installed at the Arvedi Steel Plant in Cremona, Italy. Arvedi Group is one of the leading European steelmaking companies.

The Turboden 100 HR ORC unit, designed for 10 MW nominal capacity and operated at 7.5 MW for the first years, will convert the off-gas waste heat from the steel melting Electric Arc Furnace (EAF) to electric power. The heat recovery system configuration includes a saturated steam heat carrier circuit to convey the heat from the furnace exhaust gas to the ORC unit.

This new system will be coupled to the existing Tenova Consteel® system, which heats and feeds metallic charge to a 250-ton Electric Arc Furnace (EAF), one of the largest in the world, for a combination of heat recovery and environmental sustainability. The heat recovery system will be put in operation at the beginning of 2017.

The waste heat boiler, to be supplied by Tenova, will be installed on the primary EAF off-gas line in parallel to the existing quenching tower and will produce saturated steam.

During the EAF process, the saturated steam (heat carrier) will transfer thermal power to the ORC turbogenerator working fluid, which then expands in the turbine to convert incoming thermal energy into electric power by means of an electric generator.

The main drivers for this project are the energy production valorization, with a consequent reduction in CO2 emissions of approximately 23,300 t/y, and the access to White Certificates.


Source: Turboden

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A Turboden 4 MW heat recovery ORC system will be installed in the 80 MW power station of Gibraltar, designed and supplied by Bouygues Energies & Services. This solution improves the power plant efficiency and reduces the overall life-cycle costs.

The Turboden 40 HRS ORC unit exploits the heat of exhaust gases coming from three MAN 14V51/60G gas engines (14.3 MW each), to generate 4 MW of gross electric power, achieving an overall combined cycle efficiency of 52%. Turboden will supply the ORC system including the three primary heat recovery exchangers for the direct heat transfer between the engines exhaust fumes and the ORC working fluid.

The ORC system start-up is expected in the first quarter of 2017. Once in operation, the heat recovery plant will lead to an annual saving of 42.000 Barrel of Oil Equivalent and will avoid the emission of 12.000 tons of CO2 equivalent each year.

Turboden has been developing direct heat exchange solutions for medium temperature hot gases (e.g. 600 °C) since 2009, when the first 500 kW direct exchange ORC unit was installed downstream a 7 MW diesel engine. In addition to the first unit, Turboden has supplied other 4 ORC units with direct exchange. The direct exchange solution allows avoiding the presence of intermediate circuits, leading to improved performances, lower investment cost and simpler schemes.

These applications represent an important technological innovation and provide several benefits and advantages compared to other solutions, as well as enhancing environmental sustainability, emissions reduction, industrial process efficiency and business performance. Turboden is committed to successfully deliver its ORC solutions worldwide, providing maximum quality service from commissioning to aftersales to achieve the expected performance results throughout the life of the plant” says Roberto Bini, Turboden Managing Director and R&D Manager.

In heat recovery applications, Turboden ORC units can be employed in combined cycles with reciprocating engines, with a net output increase of 8-12%, and with gas turbines, with a net output increase up to 25-45%, depending on the primary mover efficiency and on the fuel used. Turboden ORC modules can find an efficient use in these dry combined cycle projects, thanks to the good electrical efficiencies, minimum requests of operation and maintenance and simplicity of all start and stop procedures, which allow system management even by a non-licensed technician and permit operations in remote locations, with lack of water and extreme climates.

For medium temperature heat recovery (e.g. 300 °C), the ORC technology – compared to the traditional steam based solutions- leads to a relevant improvement of the net power output leveraging the perfect match between the heat source and the working fluid selected. Additionally, thanks to the characteristic of an organic compound as working fluid, the Direct Exchange ORC solution puts together the effectiveness of once-through type evaporators (high performances, fast response, low cost) to the ease of operation of the thermal media (no issue of corrosion, erosion, scaling, etc).

Turboden 35 years’ experience in the construction of ORC turbogenerators made possible the design, implementation and delivery of more than 300 power plants, with an overall power output of about 430 MWe, of which 10 units recover waste heat from internal combustion engines and from gas turbines, with a total power capacity of 13.5 MWe. The power of Turboden ORC turbogenerators in this application typically ranges between 500 kW and 15 MW electric.

SAJ Electric