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CLEAN ELECTRICITY FROM WET STEAM - …€¢ Screw expanders work where turbines can’t because they...

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CLEAN ELECTRICITY FROM WET STEAM ©Heliex Power Ltd 2012 - Confidential
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CLEAN ELECTRICITY

FROM WET STEAM

©Heliex Power Ltd 2012 - Confidential

Heliex Power Ltd.

The world leader in Rotary Steam

Engines and their use in energy

conversion and recovery.

©Heliex Power Ltd 2012 - Confidential

Heliex Power Ltd.

©Heliex Power Ltd 2012 - Confidential

Heliex spins out from City University London with

exclusive world-wide licence on steam

screw expanders and related technology.

BP Alternative Energy International invests.

Heliex establishes its operations in East Kilbride,

Scotland.

First 110kWe steam expander runs on

dynamometer.

First expander generator set

assembly begins.

Expander performance dyno test demonstrates

65% efficiency.

ESB Novusmodus invests and BP invests “catch

up”.

First generator set installed in customer’s

factory.

Jan 2010 Dec 2010 Jun 2011 Jan 2012 May 2012 2013

• Screw expanders work where turbines can’t because they can

process wet steam.

• Heliex’s expanders eliminate timing gears and other costly

components, generate at 50 or 60Hz and do not use refrigerants.

Organic Rankine Cycle

Wet Steam Screw Expanders

Turbines

Heliex Technology

©Heliex Power Ltd 2012 - Confidential

Screw Expander Technology • Technology well established (screw

compressors), now developed for

expansion.

• Simpler and more robust than turbines –

fewer parts, lower speeds, not sensitive

to steam quality.

• Rotors not damaged by wet steam or

water.

• Accepts fluctuating mass flow rates and

pressures.

• Low maintenance costs compared with

existing technologies.

• Stand-alone packaged sets from Heliex operate

fully automatically.

©Heliex Power Ltd 2012 - Confidential

N Profile

• Rack generation procedure

based on mathematical

theory of gearing

• Involute rotor profiles

• Almost pure rolling contact

between the rotors

• Low torque transmission

• Large displacement

• Short sealing line

Using “N” profile rotors, minimal lubrication is needed due to rolling motion and low contact forces between the rotors.

The process fluid can then be used to lubricate the rotors.

This results in a large cost saving for the expander by elimination of synchronising gears.

©Heliex Power Ltd 2012 - Confidential

Product Range

*dependent upon steam condition

• Maximum inlet pressure 25 bar a

• Minimum outlet pressure 1 bar a

• Maximum delta P is 15 bar (HP145) and 20 bar (HP204)

• Multiple parallel sets and two-stage combinations

Model Mass

flow

t/h

Power

kWe*

Applications

HP145 3 60-160 PRV, WHR, boiler

enhancement

HP204 8 180-500

PRV, WHR, boiler

enhancement,

Concentrated

solar thermal

©Heliex Power Ltd 2012 - Confidential

Heliex Electricity Generation

• PROCESS STEAM – Pressure reduction valve (PRV)

replacement in wide range of industries, district

heating, hospitals, etc.

• BOILER POWER ENHANCEMENT- Utilising boiler spare

steam pressure capacity.

• WASTE HEAT RECOVERY (WHR) – Piston and gas turbine

engines exhaust (biogas, AD, cogen, gensets, land fill,

marine), furnace and process flue gases, fluid cooling.

• BIOMASS –Expansion of saturated steam output from

biomass boiler systems up to 1MWe.

• CONCENTRATED SOLAR POWER (CSP) –Expansion of

wet steam output from solar thermal collectors up to

1MWe.

©Heliex Power Ltd 2012 - Confidential

Process Steam PRV Application

Fuel Boiler

Customer

process

Heat out

Pump

Steam at transmission pressure

PRV

Steam at process pressure or

venting

©Heliex Power Ltd 2012 - Confidential

Process Steam PRV Application

Fuel Boiler

Customer

process

Heat out

Pump

Steam at transmission pressure

Expander Power

Out

Generator

Bypass

Replacement of existing Pressure Reduction Valve

PRV

Steam at process pressure or

venting

©Heliex Power Ltd 2012 - Confidential

Boiler Power Enhancement

Using “spare” boiler pressure to generate electricity.

• Boiler being used under capacity e.g. operating at 8 barg but

designed for 15 barg.

• Increase boiler pressure, subject to design and control

modifications, to design pressure 15 barg.

• Pass steam through expander to return steam to original

boiler output pressure 8 barg or to original pressure

downstream of PRV e.g. 2 barg.

• Generate electricity without investment in fuel conversion capital equipment (engine, boiler and associated equipment).

©Heliex Power Ltd 2012 - Confidential

* NB. In many cases the exit enthalpy of the steam is not important and additional gas burn is not required.

** Case 3 is enhanced boiler pressure from case 2 to increase power output.

PRV Power Generation

UK Economics

©Heliex Power Ltd 2012 - Confidential

Application Case 1: PRV HP 145 Case 2: PRV HP 204 Case3: PRV +boiler power

enhancement HP 204**

Steam mass flow 2.15 t/h 5.09 t/h 5.05 t/h

Boiler pressure 13 bar a 12 bar a 16 bar a

Post-PRV pressure 2 bar a 3 bar a 3 bar a

Gross shaft power output 103 kWm 222 kWm 258 kWm

Net electrical output 93 kWe 202 kWe 235 kWe

Annual electricity value £ 69,686 p.a. £ 151,180 p.a. £ 175,906 p.a.

Boiler extra power required * 113.3 kW * 244.2 kW * 283 kW *

Annual gas extra cost * £ 25,492 p.a. * £ 54,945 p.a. * 63,800 p.a. *

Net annual income/savings * £ 41,093 p.a. * £ 90,634 p.a. * £ 112,107 p.a. *

If exit enthalpy must be maintained*:

Assumptions

Cost of gas £ 0.03 /kWh £ 0.03 /kWh £ 0.03 /kWh

Cost of electricity £ 0.10 /kWh £ 0.10 /kWh £ 0.10 /kWh

Assumed running time 7500 h/year 7500 h/year 7500 h/year

PRV Power Generation

Carbon Savings

Application Case 1: HP 145 Case 2: HP 204 Case3: HP 204

Net electrical output 93.0 kWe 202 kWe 235 kWe

Annual electrical power generated 696,895 kWh 1,511,798 kWh 1,759,067 kWh

Clean energy annual carbon saving 376 tonnes 816 tonnes 950 tonnes

If exit enthalpy must be maintained:

Annual extra gas burned 766,545 kWh 1,622,977 kWh 1,934,973 kWh

Burned gas annual carbon footprint 138 tonnes 299 tonnes 348 tonnes

Net annual carbon savings 238 tonnes 517 tonnes 602 tonnes

Assumptions

CO2 from gas 0.18 kg/kWh 0.18 kg/kWh 0.18 kg/kWh

CO2 from electricity 0.54 kg/kWh 0.54 kg/kWh 0.54 kg/kWh

Assumed running time 7500 h/year 7500 h/year 7500 h/year

©Heliex Power Ltd 2012 - Confidential

Applications – Waste Heat Recovery

©Heliex Power Ltd 2012 - Confidential

Boiler/heat

exchanger

Process

Hot water

ORC

Space heating

Pump

Steam

Generator

Hot Fluid

Cooled Fluid

Expander Power

Out

• Engine exhaust

• Furnace and

process flue gases

• Geothermal power

sites

• Concentrated Solar

Thermal arrays

WHR Power Generation

UK Economics

©Heliex Power Ltd 2012 - Confidential

Waste Heat Recovery Industrial Process Biogas Engines

(4x 1MWe)

Gas Engines

(4x 2MWe)

Engine electrical power output n/a 4 MWe 8 MWe

Heat source 3.76 MWth 3.76 MWth 7.5 MWth

Model HP145/204 HP145/204 HP204

Steam mass flow rate 4 t/h 3.5 t/h 7 t/h

Inlet/boiler pressure 25 bar a 25 bar a 20 bar a

Outlet pressure 1 bar a 1 bar a 1 bar a

Expander net electrical power output 300 kWe 286 kWe 392 kWe

Annual electricity value £ 243,632 p.a. £ 231,316 p.a. £ 316,908 p.a.

Remaining available thermal energy 2.66 MWth 2.33 MWth 4.65 MWth

Assumptions

Cost of electricity £ 0.10 /kWh £ 0.10 /kWh £ 0.10 /kWh

Assumed running time 8100 h/year 8100 h/year 8100 h/year

WHR Power Generation

Carbon Savings

©Heliex Power Ltd 2012 - Confidential

Waste Heat Recovery Industrial Process

Biogas Engines

(4x 1MWe)

Gas Engines

(4x 2MWe)

Expander net electrical output 301 kWe 286 kWe 392 kWe

Annual electrical power generated 2,436,326 kWh 2,313,168 kWh 3,169,085 kWh

Clean energy annual carbon saving 1316 tonnes 1249 tonnes 1711 tonnes

Assumptions

CO2 from electricity 0.54 kg/kWh 0.54 kg/kWh 0.54 kg/kWh

Assumed running time 8100 h/year 8100 h/year 8100 h/year

• Robust strategic technology suited to major global markets.

• Easily assimilated.

• Driven by increasing energy cost, mandatory efficiency

improvements and carbon reduction.

• Not subsidy dependent.

• 3 year or less payback.

• Beta sites in operation March 2013.

Heliex Technology Deployment

©Heliex Power Ltd 2012 - Confidential

Heliex Facilities

©Heliex Power Ltd 2012 - Confidential

Offices, Factory, Test Centre

Technology Park Location, East Kilbride

HP145 Generator Set

©Heliex Power Ltd 2012 - Confidential

Installation – Steam Venting

©Heliex Power Ltd 2012 - Confidential

Thermal oxidisation plant

Oxidisation of process wastes

Region - UK

Commissioned – May 2013

Output power – 70kWe

Operating hours - 2800

Estimated payback – 5 years

Installation – Biomass combustion

©Heliex Power Ltd 2012 - Confidential

Region - Ireland

Commissioned – Jan 2014

Output power – to 70kWe

Installation – PRV

©Heliex Power Ltd 2012 - Confidential

Industrial Process Plant

Installed in parallel with PRV

Region - Italy

Commissioned – Sept 2013

Output power – 120kWe

Operating hours - 8000

Estimated payback – 3 years

Thank-you for your attention.

©Heliex Power Ltd 2012 - Confidential


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