Turboden company profile geothermal application
Update January 2016
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The Company
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Strong technical and strategic support to Turboden on-going activities and future
development
• Focus on the energy/power business • Oriented to research and development • ORC technology complementary technical
solution for several MHI business (e.g. geothermal plants, gas turbines, etc.)
Turboden medium term business plan: larger sizes and
enhanced solutions
Turboden Board of Directors is composed of 5 members, 3 MHI senior representatives appointed members – direct and strong support to Turboden management
MHI engineering support added to Turboden engineering department for new/special solutions/projects (e.g. development of the direct exchange solution)
Worldwide presence of MHI to support Turboden activities Company development in foreign countries (e.g. after sales in Germany)
Improvement of Turboden organization [new company structure] and improvement of Turboden production capability [new warehouse] to support expected volume increase
Turboden – a Group Company of MHI
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Mitsubishi Heavy Industries is a global leader in geothermal power plant…
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> 300 ORC plants globally, 0.5 GW ORC power
The largest segment of MHI over $16 billion (in fiscal 2014)
over $40 billion (in fiscal 2014)
23 % market share
>100 units globally, >3 GW power
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500+ Turboden ORC MW worldwide Turboden’s global and proven experience
Application Plant in
Operation Under
Construction Total
no. MW no. MW no. MW Wood Biomass 226 266,6 42 82,2 268 348,8 Geothermal 6 22,7 7 62,3 13 85 Solar thermal power 0 0 4 3,7 4 3,7 Heat Recovery: Reciprocating Engines, Oil&Gas, Cement and Refractories, Metallurgy, Float Glass, Waste to Energy
28 53,4 5 11,6 33 65
Total Turboden Plants 260 342,7 58 159,8 318 502,5
Last Update: October 2015
Turboden is a leading company in the ORC field with 260 plants in operation and more than 7 million hours of operation cumulated.
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electricity
heat
Biomass
Waste-heat
Geothermal
Solar
What We Do: Organic Rankine Cycle systems
Turboden designs and develops turbogenerators based on the Organic Rankine Cycle (ORC), a technology for the combined generation of heat and electrical power from various renewable sources, particularly suitable for distributed generation.
200 kW – 20 MW per single shaft Waste to Energy
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Turboden capabilities
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• Participation in national & EU research programs
• Cooperation with EU Universities and Research Centres
• Thermodynamic cycle optimization
• Working fluid selection & testing
• Thermo-fluid-dynamic design and validation
• Implementation & testing of control/supervision software
• Many patents obtained
• Pre-feasibility studies: evaluation of technical & economical feasibility of ORC power plants
• Customized proposals to maximize economic & environmental targets
• Complete in-house mechanical design
• Proprietary design and own manufacturing of ORC optimized turbine
• Tools - Thermo-fluid-
dynamic programs - FEA - 3D CAD-CAM - Vibration analysis
• Start-up and commissioning
• Maintenance, technical assistance to operation and spare parts service
• Remote monitoring & optimization of plant operation
• Outsourced components from highly qualified suppliers
• Quality assurance & project management
• In-house skid mounting to minimize site activities
R&D Sales/marketing Design Operations &
manufacturing Aftermarket
service
EPC capability
Full Power Plant EPC
Single point responsibility
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1980 - Founded by Mario Gaia, professor at Politecnico di Milano
1998 – First ORC biomass plant in Switzerland (300 kW)
1990’s – First ORC projects in solar, geothermal and heat recovery applications
2000‘s - ORC biomass plants in Europe
2009 - United Technologies Corp. (UTC) acquires the majority of Turboden’s quotas. PW Power Systems supports Turboden in new markets beyond Europe 100 plants sold
Today - Over 300 plants in the world, 260 in operation, 200 employees, ∼80 M€ turnover (2013)
2013 - MHI acquires the majority of Turboden. Italian shareholders stay in charge of management
35 years of ORC
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Average availability is 98+% on 260 plants with about 7 millions cumulative operation working hours so far
35 years of ORC
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Selected References
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Plant type: brine + steam ORC geothermal unit
Location: Japan
Status: in operation since June 2015
Heat source: geothermal brine/steam 140°C
Cooling device: air condensers
Total electric power: 5+ MW
Working fluid: n-pentane
Recent projects: Sugawara geothermal plant in Japan
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Plant under construction: 16,5 MW Velika Ciglena (Croatia) for MB Holding
Plant type: ORC geothermal unit
Customer: MB Holding
Site: Croatia
Start up: Q4 2016
Heat source: geothermal brine and steam @170°C
Cooling device: Air Cooled Condenser
Total power: 16,5 MW on a single turbine (including a 1.5 MW NCG expansion turbine)
Working fluid: Isobutane
Scope of supply: Engineering, procurement and Construction of the full ORC powerplant,
including civil and steam-field engineering
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Plant type: 4 X Turboden 10 MW ORC units
Customer: Emerging Power Inc
Site: Mindoro Island, The Philippines
Start-up: under construction (first 10 MW foreseen for Q3/Q4 2017)
Heat source: geothermal fluid at 159°C
Cooling device: air condensers
Total power: 40 MWel net
Working fluid: Isopentane
Scope of supply: Turboden in consortium with TSK will provide the turnkey plant
Plant under construction: Montelago geothermal (Philippines) for Emerging Power
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Turboden Geothermal Plants in operation in Bavaria since 2011 with 98% availability
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1 km
Kirchstockach: 5,6 MWel
Dürrnhaar: 5,6 MWel
Sauerlach: 5 MWel + 4 MWth
Traunreut: 4 MWel + 12 MWth
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Plant type: Two level cycle geothermal unit
Customer: SWM - StadtWerke München (public utilities company) Location: Bavaria, Germany
Started-up: February 2013
Heat source: geothermal fluid at 140°C
Cooling device: air condensers
Total electric power: 5+ MWel plus 4 MWth decoupling for district heating
Working fluid: refrigerant 245fa (non flammable)
Reference Plant - Sauerlach
Off grid mode capable
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Reference Plant - Traunreut
Plant type: ORC geothermal unit
Customer: Geothermische Kraftwerksgesellschaft Traunreut GmbH
Location: Traunreut (Germany)
Status: started up in January 2016
Heat source: geothermal fluid at 118°C
Cooling device: air condensers
Total electric power: 4.1 MW
Total thermal power: 12 MW (to the district heating)
Scope of supply: Turboden in consortium with TH Arens will provide turnkey plant
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Reference Plant – SOULTZ – New unit revamping
Plant type: geothermal, 1st EU operating plant on EGS (Enhanced Geothermal System)
Site: Soultz-sous-Forêts, Alsace, France
Status: Under construction
Start-up: April 2016
Heat source: hot water at 170°C
Cooling source: air condenser
Total electric power: 1.7 MW
Scope: EPC, as consortium with TH ARENS
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Other Geothermal References
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Plant type: geothermal – experimental for Enel
Site: Castelnuovo di Val di Cecina, Italy
Year: 1992
Heat source: Geothermal fluid at 114°C (return at 102°C)
Cooling source: water/air
Total electric power: 1.3 MW
Net electric efficiency: 9%
Early Demonstration Projects
Site: Kapisha, Zambia
Year: 1988
Heat source: Geothermal fluid at 88°C
Total electric power: 2 x 100 kW
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EU Funded Demonstration Projects
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Plant type: geothermal low enthalpy, coupled with a geothermal district heating system
Site: Marktgemeinde, Altheim, Austria
Start-up : March 2001
Heat source: hot water at 106°C
Cooling source: cold water from a nearby river (cooling temperature 10/18°C)
Design electric power: 1 MW (normally operated by the owner at ~ 500 kW)
Plant type: geothermal, 1st EU operating plant on EGS (Enhanced Geothermal System)
Site: Soultz-sous-Forêts, Alsace, France
Start-up: June 2008
Heat source: hot water at 180°C
Cooling source: air condenser
Total electric power: 1.7 MW
Net electric efficiency: 11.5%
Plant type: geothermal low enthalpy, coupled with a geothermal district heating system
Site: Simbach – Braunau, German-Austrian border
Start-up: August 2009
Heat Source: hot water at 106°
Cooling source: air/water
Design electric power: 200 kW
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Plant type: geothermal Customer: AFJET (Afyon Jeotermal) Delivery date: 2016 Heat source: geothermal brine @110°C Coupled to Geothermal District Heating Cooling device: Cooling Towers Total electric power: 3 MWel Working fluid: refrigerant
Geothermal project in Afyon, Turkey
FIRST TURBINE MADE IN TURKEY
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Reference Plant - Enel Supercritical
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Plant type: geothermal prototype with supercritical cycle
Customer: Enel Green Power
Site: Livorno, Italy
Start-up: March 2012
Heat source: hot water at 150°C nominal
Cooling device: ‘dry & spray’ condenser
Total electric power: 500 kW
Working fluid: refrigerant (non flammable)
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Technical slides
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ORC Cycle is an highly convenient and versatile power generation means
Generator Turbine
Condenser CO
OLI
NG
C
IRC
UIT
Evaporator
Pump
Preheater GE
OFL
UID
C
IRC
UIT
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0
20
40
60
80
100
120
140
160 Te
mpe
ratu
re °
C
ORC FLUID
1
2
3 4
5
ADVANTAGES Superheated expansion, no liquid drops hit the blades Free positioning of the cycle with respect to critical point of fluid good matching to heat source High efficiency over the seasonal temperature variation Low O&M requirements because the rotating parts are not in contact with corrosive fluids Unattended operation
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Proven Experience in the Design of Axial Turbines
Turboden designs and manufactures
its own axial turbines
Turboden axial turbine
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15 years of Turbines experience: a careful and continuous size growth driven by geothermal market
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Turboden’s Single shaft turbines power output over time kW
Units in operation / under construction
Maximum shaft power output available
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2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2015
318 ORC Turbines, 0,5 GW ORC power, 7 Mio operation hrs @ availability > 98%
MB Holding
Mindoro
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Technical Advantages of Turboden proprietary turbine
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A MORE EFFICIENT CHOICE • Average turbine isentropic efficiency: 85 to 90 % • Multi stage (4- 5 stages) axial turbines are less sensitive than
radial ones to discharge pressure variations, showing nearly constant efficiency over wide range of operating conditions
A RELIABLE TURBINE • Average plant availability > 98% on all the Turboden fleet • Operating speed: From 1500 rpm to 3000 rpm • Robust design, low rpm, and strict quality tests by Mitsubishi • Patented seals & bearing replacing system: short maintenance
procedures • Specialized local staff for maintenance
A PROVEN SOLUTION • The design of the turbine is carried out by Turboden representing the core know-how since 1980 • 318 Turboden ORC turbines successfully implemented with sizes from 200 kW to 20 MW • Proven experience with 9 different ORC fluids • Axial geometry is a traditional configuration, the most widely adopted in turbomachinery design, proven
with millions of working hours worldwide
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Turboden technology
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• Geothermal resource-based organic fluid selection (proven operation experience with 9 different fluids; cooperation with research centres for fluids testing)
• In-house thermo-dynamic cycle definition and optimized design of the turbine (axial multi-stages)
• Tailored design of the full ORC package based on a consolidated supply chain and proven solutions
• Customized project-based mechanical design of the plants
• Continuous design review based on information coming from field tests on working plants
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• Exploitation of resources from 90°C
• Unit size up to 20 MW per single turbine (40 MW on a single generator)
• Slow rotating turbines (1500 rpm)
• Multi stages axial overhung turbine
• Off grid capability
• Air or Water cooling
• Cogeneration Heat & Power solutions
• Wide selection of working fluids (also non-flammable)
• Patented seals & bearing replacing system ensures short maintenance procedures
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Turboden technology
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After Sales
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Turboden After Sales Service organization
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AR Remote support
MS
Scheduled maintenance
TOS
Turboden online service
U
Replacement of wear parts
F
Replenishment of organic fluid
AV_gar
Guarantee of Availability
PG
Extension of the
Guarantee on the main
components
GS
Standard Guarantee
R_min
Mini kit of spare parts
The team: 5 Commissioning Engineers 14 Service Engineers 13 Service Technicians + 4 partners company with field Service Technicians
The Customers: 260 Plant in operation Worldwide 28 plants to be started up in 2015
1 Service Office in Germany opened in 2014 with 3 Field Engineers 1 Service Office in Ankara with 3 Field Engineers
Typical Service scheme used for EU Customers
After Sale Service
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Assistance with remote supervisor PC
The turbogenerator supervisor PC is connected to Turboden headquarters in Brescia via ADSL and through Teamviewer Manager Software.
The Service staff can control the ORC working parameters, make remotely adjustments, remove defects, optimize the ORC's performance and give technical support to customer operators.
Historical trend analysis
Ideas comparison and discussion
Shared Diagnosis and Reaction Plan
customer
ORC Operation and Maintenance – Operational logs + remote monitoring
After Sale Service
Remote control
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THANKS FOR YOUR ATTENTION
www.turboden.com