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CASE STUDIES
ORGANIC RANKINE CYCLE FOR
GEOTHERMAL

GEOTHERMAL - BAGNORE

CLIENT NAME: Enel Green Power
PLANT LOCATION: Bagnore (Tuscany), Italy
DATE OF IMPLEMENTATION: December 2012
PLANT SIZE 1 MWe
APPLICATION: Geothermal
MODEL USED: GEX 110
FLOW OF GEOTHERMAL STEAM: 12 t/h
TEMPERATURE OF GEOTHERMAL STEAM: 150 C°
WATER OR COOLING AGENT: cooling water from cooling towers 
GENERATOR VOLTAGE: 6 kV
INSTALLATION: Outdoor 

Enel was looking to utilize the untapped potential of an existing geothermal resource located in Bagnore, Tuscany (Italy). A compact binary installation was needed to fit seamlessly with a 20 MW single flash plant already in place. 

Exergy's solution was a fully integrated binary cycle system. By selecting a binary system the client ensures the steam never impacts the turbine directly, greatly reducing maintenance and wear and tear compared with steam turbines.

Exergy's technological innovation facilitated the use of a geothermal source previously thought unsuitable due to the low temperature of the primary fluid (100-180 C°). As a result Exergy have provided superior energy efficiency compared to traditional solutions.

The Bagnore plant now produces electricity with zero emissions to approximately 2,500 households and in the process prevents emission of 4.200 tons of CO2 and the consumption of 1.600 tons of oil equivalent per year. 

 

 

ORGANIC RANKINE CYCLE FOR
BIOMASS

BIOMASS - AREZZO

CLIENT NAME: BET Del Tongo Cucine
PLANT LOCATION: Arezzo (Tuscany), Italy
DATE OF IMPLEMENTATION: 2012
PLANT SIZE 1 MWe
APPLICATION: Biomass
MODEL USED: HREX 110
INSTALLATION: Outdoor 

The client producing wood furniture was looking to utilize the untapped potential of wood waste from their production to produce electricity, develop a greener and more economically efficient business model and a secondary revenue stream by selling electricity back to the grid. 

The solution provided by EXERGY was an ORC unit with the Radail Outflow Turbine that utilizes the heat coming from a boiler to convert waste wood from furniture production into clean energy. 

 

ORGANIC RANKINE CYCLE FOR
BIOMASS

BIOMASS - VENOSA

CLIENT NAME: Energia Vulture Alto Bradano S.r.l.
PLANT LOCATION: Venosa (PZ), Italy
DATE OF IMPLEMENTATION: 2012
PLANT SIZE 990 kWe
APPLICATION: biomass
MODEL USED: EP110 ERS  
QUANTITY OF BIOMASS: 16000 t/y
WATER OR COOLING AGENT: direct air cooling
THERMAL MEDIUM: thermal oil
GENERATOR VOLTAGE: 400 V
INSTALLATION: Outdoor

 

The client Energia Vulture Alto Bradano, had two requirements when they partnered with EXERGY. Their first requirement was to dispose of waste from grape and olive production and waste from the local wood processing industry using environmentally friendly methods. Their second requirement was to operate their business in a more economically efficient way and develop a secondary revenue stream by selling electricity back to the gird. 

EXERGY provided a packaged ORC unit which when combined with a thermal oil boiler would efficiently convert the agricultural waste into electricity. The ORC unit has an automated control system, ensuring minimal staff monitoring, thus making the operation simple to manage for the client. 

The unit integrated well into the surrounding environment and met with the appropriate emission requirements, The unit was air cooled and due to the inclusion of the EXERGY Radial Outflow Turbine it operated at an extremely high efficiency level (up to 24%) compared with similar installations on the market. 

 

ORGANIC RANKINE CYCLE FOR
GEOTHERMAL

GEOTHERMAL - PAMUKOREN

CLIENT NAME: ÇELIKLER JEOTHERMAL
PLANT LOCATION: Pamukören, Turkey
DATE OF IMPLEMENTATION: 2013 - 2014
PLANT SIZE: I, II, III IV each 22.5 MW (90 MW in total)
APPLICATION: geothermal
MODEL USED: GEX TM
FLOW OF GEOTHERMAL STEAM: 1.400 t/h
TEMPERATURE OF GEOTHERMAL STEAM: 178 C°
TYPE OF FLUID: steam/brine
GENERATOR VOLTAGE: 11 kV
INSTALLATION: Outdoor

The client Çelikler Jeothermal Elektrik Uretim A.S. are active in the energy, construction and mining sectors. The Pamukören geothermal fields of the Menderes basin (Turkey) have a large potential for electrical production due to high enthalpy levels and the abundance of resources in the area. Çelikler were looking to develop a series of new power plants in Pamukören and to create a new project in the Sultanhisar region. They were looking to realize a total of 120 MW over 6 new geothermal power trains. 

The proposal presented by EXERGY and its consortium partners (Atlas Copco and SPIG) was selected due to the high level of efficiency achievable and an intelligent plant design. As a result, future maintenance has been simplified and resources revenues maximized. EXERGY, working in cooperation with experienced and respected partners were responsible for the process design and supply of the entire power cycle , providing the best overall solution to the client. 

EXERGY's strong performance during the execution phase of the project has led the client to order further units for adjoining installations. 

After a successfull operation of the Pamukören I and II modules, Çelikler opted to undertake an extension of the Pamukören III and IV modules plus a new project in Sultanhisar with the same partners and technology utilized. Thanks to the Pamukören and Sultanhisar projects Çelikler is the biggest player in the binary geothermal energy production in Turkey today and together with EXERGY will deliver more than 1000 GWh per year of renewable energy to the Turkish energy grid.

 

ORGANIC RANKINE CYCLE FOR
HEAT RECOVERY

HEAT RECOVERY - UDINE

CLIENT NAME: Danieli Environment
PLANT LOCATION: Pozzuoli del Friuli (UD), Italy
DATE OF IMPLEMENTATION: 2014
PLANT SIZE max 1.2 MWe
APPLICATION: Heat recovery (steel mill)
MODEL USED: EPSd 110
WATER OR COOLING AGENT: cooling water from cooling tower
GENERATOR VOLTAGE: LV
INSTALLATION: Outdoor

The client Danieli Environment is the division of Danieli specialized in the environmental protection offering proprietary technologies for water treatment, air pollution control, energy saving and more.The final user is ABS Acciaierie, a still mill plant located in the north of Italy. With the increasing cost of energythe client was looking for ways to improve the energy efficiency of the final user as well as reducing the impact on the environment of the plant. 

EXERGY's solution  was the installation of the ORC system for waste heat recovery with EXERGY's Radail Outflow Turbine. The ORC technology is applied to the electric arc furnace (EAF) and, by exploiting the hot waste gas generated by the steel mill, it produces 1 MWe. The heat from the waste gas is extracted using an intermediate fluid which then vaporizes the organic fluid in the ORC abstorbing the energy, before passing the turbine. Here it expands, causing the turbine to spin and creates electricity at the generator. By installing EXERGY's EPSd Radial Outflow Turbine, the client was able to recover the maximum amount of energy, thus increasing the electrical efficiency of the installation.

The ABS plant now produces electricity with zero extra emission saving 4.692 tons of COand 1.499 tons of oil equivalent per year. 

 

ORGANIC RANKINE CYCLE FOR
GEOTHERMAL

GEOTHERMAL - DENIZLI

CLIENT NAME: AKÇA ENERJI
PLANT LOCATION: Saraykoy Denizli, Turkey
DATE OF IMPLEMENTATION: 2015
PLANT SIZE 4 MWe
APPLICATION: geothermal
MODEL USED: GEX 350
FLOW OF GEOTHERMAL STEAM: 8.8 t/h 691,2 t7h
PRESSURE OF GEOTHERMAL STEAM: 3.5 bar
TEMPERATURE OF GEOTHERMAL STEAM: 105 C°
TYPE OF FLUID: steam/brine
GENERATOR VOLTAGE: 6 kV
INSTALLATION: Outdoor

The client, AKÇA ENERJI, is part of the AKÇA Holding, which is a Turkish diversified business ranging from the textile industry to agribusiness. AKÇA ENERJI is the holding’s energy division. In this case, the client was looking to utilize the untapped potential of an unexploited existing geothermal resource.

EXERGY’s solution was the world’s first ORC binary installation equipped with 2-pressure-level cycle on a single-disk turbine.

The geothermal fluid is passed through the first sequence of HIGH pressure heat exchangers, passing enthalpy to the organic fluid. This organic fluid vaporizes and is passed through the HIGH pressure EXERGY turbine Inlet. Then the geothermal fluid is passed through the second sequence of LOW pressure heat exchangers, vaporizing the organic fluid, which is then passed through the LOW presure EXERGY turbine Inlet.EXERGY turbine, fed by HIGH and LOW pressure organic fluid steam, drives a generator to produce electrical power. The geothermal fluid is then reinjected back into the ground.

EXERGY’s technological innovation facilitated the efficient use of a geothermal source previously thought unsuitable due to the low temperature of the primary fluid (105 C°/220 F°).

The AKCA plant now produces electricity with zero emissions saving 16,422 tons of CO2 and 5,248 tons of oil equivalent per year.

ORGANIC RANKINE CYCLE FOR
HEAT RECOVERY

HEAT RECOVERY - TARGOVISHTE

CLIENT NAME: Area Impianti
PLANT LOCATION: Targovishte, Bulgaria
DATE OF IMPLEMENTATION: 2015
PLANT SIZE: 5 MWe
APPLICATION: Heat recovery (glass mill)
MODEL USED: EPS 500
INLET TEMPERATURE OF TERMAL OIL: 300°C
OUTLET TEMPERATURE OF THERMAL OIL: 150°C
COOLING TYPE: direct air condenser
GENERATOR VOLTAGE: MV
INSTALLATION: Outdoor

The client Area Impianti is an Italian solution provider for flue gas treatment and heat recovery systems.The final end user is Sisecam, a Turkish company leader in glass production. EXERGY and Area Impianti provided 3 ORC based heat recovery systems to be installed on existing glass plants, 2 in Turley and one in Bulgaria, Targovishte.

The ORC technology provided by EXERGYapplied to the float glass mill in Targovishte exploits the hot fumes generated to produce 5 MWe electricity.The ORC system works by the vaporizing of the organic fluid absorbibg the energy from the intermediate fluid and then passing to the turbine. Here it expands, causing the turbine to spin and creates electricity at the generator. Sisecam and Area Impianti's choice to install EXERGY's highly efficient EPS Radial Outflow Turbine revealed the best solution to harness the maximum amount of waste heat and increase the electrical efficiency of the installation.

Today the Sisecam Targovishte plant produces "greener" electricity, saving 20,000 tons of COand 7,500 tons of oil equivalent per year. The high efficiency of the EXERGY product reduces the plant's energy consumption and carbon footprint contribution positively to the environment.