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E-RATIONAL is a BEP Europe division E-RATIONAL | Ten Briele 6 | 8200 Brugge | Belgium | T +32 50 40 85 40 | F +32 50 38 01 60 | www.e-rational.net
| Date post: | 24-Jun-2015 |
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E-RATIONAL is a BEP Europe division
E-RATIONAL | Ten Briele 6 | 8200 Brugge | Belgium | T +32 50 40 85 40 | F +32 50 38 01 60 | www.e-rational.net
Turning waste heat
into
Clean Energy
WWW.BEPCO.COM
BURKE E PORTER | Global Organization
BEP Europe employs over 100 people
7,500 square meter manufacturing area capable of
fabrication, machining and final assembly.
Burke E Porter, the corporate headquarters,
employs over 100 people
9,750 square meter manufacturing area capable of
fabrication, machining and final assembly.
BEP Wuxi employs over 75 people
3,700 square meter manufacturing area capable of
fabrication, machining and final assembly.
Burke E Porter, ww employs over 450 people
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Turnover in US$ Sales in USD
BURKE E PORTER | Turnover History
BEP in numbers…
Fiscal year ends on March 31
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Overview
BEP Europe | Products
End-of-Line Production Test Systems for :
Wheel alignment (toe, camber, caster)
Headlight Aiming
Roll & Brake
Rattle & Twist
Driver Assistance
Powertrain & drivetrain
Wheel & Tire Assembly Systems
Vision Systems, Machine Control & Data Acquisition Systems
Dynamometers
Chassis Dynamometers
Emission Testing, Mileage Accumulation, Climatic/Wind Tunnel, Noise, Vibration and Harshness, Research & Development
Powertrain Dynamometers
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Germany
Audi - Ingolstadt,
Neckarsulm
Daimler/Chrysler –
Bremen
Opel – Eisenach,
Rüsselsheim
Volkswagen – Emden,
Wolfsburg, Hannover,
Mosel…
Great Brittan
IBC – Luton
Jaguar – Castle
Bromwich
Ford -
Southampton
France
PSA – Aulnay, Mulhouse,
Rennes, Sochaux, Sevel
Nord
Renault – Guyancourt,
Dieppe, Douai, Flins,
Maubeuge
Toyota – Valenciennes
Bugatti - Molsheim
Spain
Ford – Valencia
Nissan – Barcelona
Opel – Zaragoza
PSA – Vigo
Renault – Palencia, Valladolid
Italy
Lamborghini – St. Agata
Bolognese
Fiat – Sevel Sud
Sweden
Volvo - Goteborg
Poland
Daewoo – Warschau
Fiat – Tichi
Volkswagen - Poznan
Czech Republic
Toyota – Kolin Hyundai – Ostrava Slovakia
Volkswagen – Bratislava
Kia - Zilina
Hungary
Audi – Gyor
Russia
Tagaz – Rostov
Avtovaz – Toliatti
Toyota – St. Petersburg
Volkswagen – Kaluga
GM – St. Petersburg
Hyundai – St. Petersburg
Turkey
Renault – Bursa
Hyundai - Izmir
Romania
Renault – Dacia
Slovenia
Renault – Revoz
Serbia
Fiat - Kragujevac
BURKE E PORTER | Customers in Europe
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USA
VW Chattanooga
Russia
General Motors,
Hyundai & TMMR St.
Petersburg
VW Kaluga
China
Dongfeng Peugeot
Citroën, Wuhan
VW, several sites
Thailand
General Motors,
Rayong
VW
Malaysia
VW
Brazil
PSA Porto Real
Renault Curitiba
VW Taubaté
VW Anchieta
VW Curitiba
Argentina
PSA Palomar
VW Pacheco
Renault Cordoba
India
VW Pune
Indonesia
PT Astra France
Motor, Jakarta
Morocco
Somaca, Casablanca
Renault, Tanger
Syria
Siveco, Homs
South Africa
FMCSA, Pretoria
General Motors, Struandale
VW Uitenhage
BURKE E PORTER | Customers Worldwide
More Waste Heat available from US Industry than all renewable energy sources combined
Energy Concern
Organic Rankine Cycle
• Rankine cycle, Steam cycle = high temperature & pressure
• Organic: use of cooling fluid = ‘Low’ temperature
• Waste heat transformed into electricity
• Working range ORC-medium: 80-150°C
ORGANIC CYCLE with REFRIDGERATOR
Organic Rankine Cycle
“Fuel” for ORC?
• Waste heat which is lost anyway:
• Engines, CHP (gas, bio gas, diesel, …): jacket cooling + exhaust gas
• Low pressure (waste) steam
• Industrial processes:
• Steel, glass industry
• Combustion processes (bio fuel, waste incineration )
• Exothermic processes in chemical industry
• Petrochemical industry: cool down distillates
• Power plants
• Geothermal applications, District heating, CSP
• Fluids and gases
Examples of Waste Heat flows - 1 Hot water:
Flow: 27,78 kg/s (100 m³/h / 440 GPM) Specific heat capacity water: 4,19 kJ/kgK T: cool down from 130°C to 90°C (266°F- 194°F) Thermal Power: 4 656 kWth / 15.9 MMBTU/h
Thermal oil:
Flow: 2,27 kg/s (11m³/h / 48 GPM) Specific heat capacity 2,5 kJ/kgK, Density: 742 kg/m³ T: Cool down from 200°C to 100°C ( 392°F- 212°F) Thermal Power: 567 kWth / 1.93 MMBTU/h
Examples of Waste Heat flows - 2
Low Pressure Steam: Flow: 0,8 kg/s (2,8 T/h) / 1,76 Lbs/s Evaporation heat 2106 kJ/kg at 150°C / 302°F T: Cool down from 150°C/ 302°F till 100°C/ 212°F and condense Thermal Power: 1 391 kWth / 4.75 MMBTU/h
Flue gases: Flow: 20,72 kg/s (100 000 Nm³/h) Specific heat capacity air at 200°C/ 392°F: 1,026 kJ/kgK, Density at 200°C/ 392°F: 0,746 kg/m³ T: Cool down from 260°C till 160°C ( 500°F- 320°F) Thermal Power: 2 126 kWth / 7.25 MMBTU/h
Efficiency of E-Rational ORC - 2
Carnot Efficiency : Whereas T1 is Hot Side (K) T2 is Cold Side (K) Carnot for cold side: i.e. 25°C/ 77°F = 298 K 400°C/ 752°F: 55,7% 30% (Power Plant) 200°C/ 392°F: 36,9% 120°C/ 248°F: 24,3% ORC: 8,5 – 11 % 90°C/ 194°F: 17,9% ORC: 6-9%
E-Rational ORC-1000 series
ISO US Metrics
Thermal Power Max 1000 kW 3.4 MMBTU
Heat source Hot Water, Thermal oil, Low Pressure steam
Input temperature 85°C-150°C 176°F-303°F
ORC Fluid Honeywell r245fa or Solkatherm SES36
Generator
Asynchronous 3 x 400 VAC 50 Hz
Asynchronous 3 X 480 VAC 60 Hz
Power Range Generator 55 - 70 - 90 - 110 - 132 kWe
Size L x W x H (mm) 10-20 Ft - High Cube
2,991 x 2438 x 2591 6058 x 2438 x 2896
2,991 x 2438 x 2591 6058 x 2438 x 2896
Weight kg/ Lbs 3,800 – 7,600 8,375 – 16,750
E-Rational ORC-1000/90 kWe (10 Ft) Skid - Model 2013
E-Rational ORC-1000/90 kWe (20 Ft) Container Model 2013
E-Rational ORC-4000
ORC-4000 series • One main platform, size 20 Ft Container • Outdoor use • Extended software control • Controlled and Seamless connection on the grid • Efficiency Depending on working conditions 6-13% • Expander- Generator set according to working conditions and available heat. Range 250kW-500 kWe • Asynchronous generator. • Built according to PED 97/22/EG • Option: Atex generator and work conditions
E-Rational ORC-4000 series
ISO US Metrics
Thermal Power Max 4000 kW 13.6 MMBTU
Heat source Hot Water, Thermal oil, Low Pressure steam
Input temperature 85°C-150°C 176°F-303°F
ORC Fluid Honeywell r245fa or Solkatherm SES36
Generator
Asynchronous 3 x 400 VAC 50 Hz
Asynchronous 3 X 480 VAC 60 Hz
Power Range Generator 250 -315-370-400- 450-500 kWe
260-300- 370- 400- 440-500 kWe
Size L x W x H (mm) 30-40 Ft - High Cube
9125 x 2438 x 2591 12192 x 2438 x 2896
9125 x 2438 x 2591 12192 x 2438 x 2896
Weight 15-25,000 kg 30-55,110 Lbs
E-Rational ORC-4000/250 kWe (20 Ft) Model 2012
E-Rational ORC-4000/260 kWe (30 Ft) Model 2014
E-Rational ORC-4000/260 kWe (30 Ft) Model 2014
ORC Software control
ORC Software control
ORC Software control
ORC Safety control
Software: Working Parameters set-up per machine
ORC Safety control
Hardware: Safety Valves
Electrical: Emergency stops
E-RATIONAL is a BEP Europe division
E-RATIONAL | Ten Briele 6 | 8200 Brugge | Belgium | T +32 50 40 85 40 | F +32 50 38 01 60 | www.e-rational.net
Industrial Heat Recovery Applications
Industrial Heat Recovery Application -1
Alstom, Norway (65°47’2”N) • International engineering company • Patented exhaust heat recovery in Aluminum Factories • ORC Pilot Project ORC1000-90 kWe
• Alcoa Aluminum Factory in Mosjøen, Norway • Hot water 90°C-70°C / 194°F-158°F • Thermal power 350 kW-1000 kW /1,2 -3,4MMBTU/hr • Cooling: cold water from Fjord 13°C/ 55°F • Power production 30-70 kWe (according to heat input)
• Pilot plant for proof of concept. • Operational June 2013 • Fairbanks: 64°50’37”N • Arctic Circle: 66°33’39”N
Industrial Heat Recovery Application - 1
Industrial Heat Recovery Application - 1
Industrial Heat Recovery Application - 2
Industrial Heat Recovery Application - 2
Proviron Base Chemicals, Ostend Belgium • Exothermic chemical process • Waste Steam recovery:
• Low pressure waste steam 3,5 bar max 3,5 T/h • Cooling: cold water • Power production: 200 kWe net • Yearly production > 1500 MWhe • > 1000 Tonnes CO2 Reduction per year • Water saving > 27000 m³/year
• Type: E-Rational ORC-4000/250 kWe ATEX • Operational since May 2012.
Industrial Heat Recovery Application - 2
Geothermal Applications
Geothermal Applications
• Source = medium to low enthalpy geothermal sources
• Water temperatures between 100 and 150 °C
• Power Plants : • Producing Electricity, opportunity to re-use cold side heat for nearby SPA, glasshouses, etc. if required • Low installation costs and low O&M requirements. • Ideal for small operators i.e. 250 kWe to 5 Mwe wanting to put the ORC next to the heat source • Simple and unattended operation
Biogas Applications
Biogas Application - 1
Biogas Application - 1
Vanheede Environmental Services, Quévy Belgium • Digester + 3 Biogas CHP Engines • Waste heat recovery from Engines (2 x 716 kWe + 1 x 1000 kWe)
• Hot water 88°C / 190°F • Heating of Digesters • Building heating • Water for showers,… • Remaining heat goes to ORC (320-450 kW/ 1-1.5 MMBTU/h)
• Cooling: air condenser • Power production: 40 kWe net • Yearly production > 340 MWhe • > 240 Tonnes CO2 reduction per year
• Type: E-Rational 1000-55kWe • Operational since July 2012
Biogas Application - 1
Biogas Application - 1
Biogas Application - 1
Biomass Applications
Biomass Applications
• Biomass = free fuel
• available nearly everywhere • can be stored for a long time • usually is free or wasted anyway
• CHP (Combined Heat and Power Plants) • Producing both Heat and Electricity • Possibities to re-use cold side heat,
• i.e. glass-houses, drying installations, chicken farm floor heating, .. • District Heating Networks for villages nearby • Saw dust drying • Swimming pools, hot springs, etc.
Biomass Application - 1
Biomass Application - 1
Centre Aquatique de Virton, Belgium
• Integration of ORC in heating of public swimming pool • ORC Project Type: ORC-500/30 kWe
• Hot water 90°C-70°C/ 194°C- 158°F • Thermal load 300 kW / 1.02 MMBTU/hr • Cooling: Swimming pool floor heating 35°C/ 95°F • Power production 22 kWe
• Delivery planned May 2014
Centre Aquatique de Virton
ORC 90°C
70°C
35°C
30°C Heat
exchanger
- Heating of public swimming pool - Re-use of ORC cooling side very efficient application
Pellet boiler
Heat exchanger - Shower
- Central heating system
Pool water ORC500 – 22kWe Hot water 300kWth 22 kWe production
Biomass Application - 2
Holzheizkraftwerk Hövelhof, Germany • Wood factory with saw dust as waste material • Wood fired boiler 5 MWth / 17.6 MMBTU • 1 MWe Turboden High temperature ORC (300°C/ 572°F) • Cooling of Turboden is heat input for E-Rational ORC • ORC Project Type: ORC-4000/315 kWe
• Hot water 90°C-70°C/ 194°F-158°F • Thermal load 4000 kW / 13.6 MMBTU • Cooling water circuit: Air cooled condensers • Power production 315 kWe
• Delivery done April 2014
Biomass Application - 3
Biomass Application - 3
Holzheizkraftwerk Oerlinghausen, Germany • Biomass boiler (wood) 3 MW/ 10,2 MMBTU/hr • Turboden 620 kWe High temperature ORC (>300°C / 572°F oil) • Cold side of Turboden powers district heating net (90°C-70°C / 194°F-158°F) • Excess heat in district heating to power E-Rational ORC • ORC 1000-90 kWe
• Thermal load: Max 1000 kW / 3.4 MMBTU/hr • Hot water from district heating (Excess heat) • Temperature: 90°C-70°C / 194°F-158°F • Cooling: Air condenser • Power production 70 kWe
• Delivery done March 2013
Turning waste heat
into
Clean Energy
Pre-study examples
Pre-study examples
1. Campine Belgium 2. Geothermal Application 3. District Heating Solution
Pre-study examples
1. Campine Belgium 2. Geothermal Application 3. District Heating Solution
Campine Beerse
- Amount of heat eliminated at quench? - Heat recuperation? - Process fluctuations? - Implementation possibilities on site? - Process impact?
Furnace
After burners
Quench
Mixing chamber Bag house
filter
Stack
Water
Air
1000°C
400°C 200°C
140°C
Furnace
After burners
Quench
Mixing chamber
Baghouse filter
Stack
Water
Air
ORC ORC4000 – 400kWe Hot water 3.5MWth Production 385kWe
Shell & tube Heat exchanger
ORC
1000°C
400°C
Air
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rs
ORC4000 – 400kWe Hot water 3.5MWth Production 385kWe
150°C
120°C
200°C 140°C
bypass
Campine Beerse
Pre-study examples
1. Campine Belgium 2. Geothermal Application 3. District Heating Solution
E-Rational Applications
Geothermal project De Kempen, Belgium •4 geothermal production wells •Geothermal brine temperature ≈ 124 °C •Return temperature to well ≈ 65°C •Available flow = 210 m³/h @ 16 – 21 bara •Heat recuperation by ORC •No cooling circuits available •Pre-study Available heat 11.15 MWth/ production well Total amount of heat = 44.6 MWth Local or centralized heat recovery?
Geothermal project De Kempen
•Geothermal brine contains salts and particles •No direct injection into heat exchangers of the ORC
Installation of extra heat exchanger(s) hot water circuit
•Compare smaller temperature differences
Geothermal project De Kempen •3 ORC machines •Parallel flows •3x ORC4000 •Total production = 960 kWe
Geothermal project De Kempen •3 ORC machines •Parallel flows •3x ORC4000 •Total production = 706 kWe
Geothermal project De Kempen •3 ORC machines •Serial flows •3x ORC4000 •Total production = 988 kWe
Geothermal project De Kempen •3 ORC machines •Serial flows •3x ORC4000 •Total production = 701 kWe
Geothermal project De Kempen
Cooling Ambient T
Parallel (65°C)
Parallel (85°C)
Serial (65°C)
Serial (85°C)
-10°C 9.30% 9.77% 9.43% 9.89%
0°C 8.74% 9.55% 8.88% 9.56%
10°C 7.40% 8.95% 7.78% 9.02%
35°C 3.23% 4.21% 4.56% 5.02%
Comparing efficiencies for different cooling temperatures:
Pre-study examples
1. Campine Belgium 2. Geothermal Application 3. District Heating Solution
E-Rational Applications
Holzheizkraftwerk Oerlinghausen, Germany •Biomass boiler (wood) 3 MW •Turboden 620 kWe High temperature ORC (>300°C oil) •Cold side of Turboden powers district heating net (90°C - 70°C) •Excess heat in district heating to power E-Rational ORC •ORC 1000 - 90 kWe
•Thermal load: Max 1000 kWth •Hot water from district heating (Excess heat) •Temperature: 90°C-70°C / 194°F-158°F •Cooling water circuit: Air cooled condenser •Power production 70 kWe
•Delivery January 2014
Holzheizkraftwerk Oerlinghausen
ORC
ORC
>300°C
Holzheizkraftwerk Germany, Oerlinghausen Biomass (wood) boiler 3MWth
District heating net
90°C
70°C
Turboden High temperature ORC Oil: >300°C 620kWe production ORC1000 – 90kWe
Hot water 1MWth 70 kWe production
Air
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Holzheizkraftwerk Oerlinghausen
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E-Rational BEP Europe NV Ten Briele, 6 B-8200 Brugge, Belgium Email: [email protected] Phone: +32 50 408 540 Website : www.e-rational.net
BEP Europe
