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
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