WHR

Waste Heat Recovery

Turboden ORC units can produce electricity by recovering heat from industrial processes and in combined cycles with reciprocating engines and gas turbines. The power of Turboden turbo generators in this application generally ranges up to 20 MW electric per single shaft.

26

plants*

59.8

MWe total

2010

first plant delivered

*6 plants are under construction

In heat recovery applications, Turboden ORC units can be a valuable way to convert residual, low-grade heat into useful power in:

HEAT RECOVERY FROM PRODUCTION PROCESSES

Heat recovery from cement production
  • High cycle efficiency up to 25%
  • Heat input from gaseous, liquid and condensing streams starting from 100°C
  • Ease of integration into the industrial process, not affecting the production
  • No impact on prime equipment (engine, gas turbine) operation

TYPICAL APPLICATIONS

ORC size location customer status notes
2 MWe Ait Baha, Morocco Ciments Du Maroc In operation since 2010 Electric power production from waste heat in cement production process + CSP (Hybrid plant)
4 MWe Aleşd, Romania Holcim SA In operation since 2012 Electric power production from waste heat in cement production process
5 MWe Rohožník, Slovakia CRH In operation since 2014 Electric power production from waste heat in cement production process
3.8 MWe Fieni, Dâmboviţa County, Romania S.C. CARPATCEMENT HOLDING S.A. (Heidelberg group) In operation since 2015 Electric power production from waste heat in cement production process
2.3 MWe Switzerland ABB Schweiz AG In operation since 2016 Electric power production from waste heat in cement production process
2.0 MWe Piacenza, Italy Industria Cementi Giovanni Rossi Under construction Electric power production from waste heat in cement production process

TYPICAL APPLICATIONS

ORC size location customer status notes
2.7 MWe Riesa, Germany ESF Elbe Stahlwerke Feralpi GmbH In operation since 2013 Electric power production from waste heat in steel industry (Electric Arc Furnace)
0.7 MWe Singapore NatSteel Holdings Pte Ltd In operation since 2013 Electric power production from waste heat in steel industry (Rolling mill)
2.2 MWe Brescia, Italy ORI Martin S.p.A. In operation since 2016 Electric power production from waste heat in steel industry (Electric Arc Furnace)
2.5 MWe Nagoya, Japan Mitsubishi Heavy Industries / Aichi Steel Under construction Electric power production from waste heat in steel industry (Electric Arc Furnace)
10 MWe Cremona, Italy Arvedi S.p.A. Under construction Electric power production from waste heat in steel industry (Electric Arc Furnace)

TYPICAL APPLICATIONS

ORC size location customer status notes
1.3 MWe Cuneo, Italy Gea Bischoff/AGC In operation since 2012 Electric power production from waste heat in float glass production process
0.5 MWe Villotta di Chions (PN), Italy BDF Industries In operation since 2015 Electric power production from waste heat in container glass production process

TYPICAL APPLICATIONS

ORC size location customer status notes
0.8 MWe Radenthein, Austria Veitsch-Radex GmbH & Co In operation since 2009 Electric power production from waste heat in refractory production process
1.7 MWe Germany undisclosed Under construction Electric power production from waste heat in aluminum industry
0.7 MWe Torbole Casaglia (BS), Italy Fonderia di Torbole In operation since 2016 Electric power production from waste heat in a cast iron cupola furnace

HEAT RECOVERY IN COMBINED CYCLES

Turboden waste heat recovery in combined cycles

In combined cycles, Turboden ORC units can be installed at the bottom of:

  • Gas turbines, with up to 40% of additional power
  • Reciprocating engines, with up to 15% of additional power

In both cases the combined cycle reaches an efficiency greater than 50%.

TYPICAL APPLICATIONS

ORC size location customer status notes
1.8 MWe Pisticci (MT), Italy Ricciarelli SpA In operation since 2010 Electric power production from waste heat from 3x8 MWe Wärtsilä diesel engines
0.6 MWe Pavia, Italy Termoindustriale SpA In operation since 2008 Electric power production from waste heat from 1x8 MWe MAN diesel engine
4 MWe Pisticci Scalo (MT), Italy Ricciarelli SpA In operation since 2012 Electric power production from waste heat from 2x17 MWe Wärtsilä diesel engines
0.6 MWe Portogruaro (VE), Italy Cereal Docks In operation since 2012 Electric power production from waste heat from 1x7 MWe Wärtsilä diesel engine
0.5 MWe Catania, Italy E&S Energy SpA Off Electric power production from waste heat from 2x1 MWe JGS/GE gas engines + 3x0.8 MWe JGS/GE gas engines + 1x0.6 MWe JGS/GE gas engine - Landfill gas
1 MWe Senden, Germany AGO AG Energie + Anlagen In operation since 2012 Electric power production from waste heat from 2x2 MWe JGS/GE gas engines (+ additional heat from the process)
0.6 MWe Kempen, Germany Stadtwerke Kempen GmbH In operation since 2012 Electric power production from waste heat from gas engines
1 MWe Chivasso (TO), Italy Ricciarelli SpA In operation since 2012 Electric power production from waste heat from 1x17 MWe Wärtsilä diesel engine
1.3 MWe Ämmässuo, Espoo, Finland HSY In operation since 2011 Electric power production from waste heat from 4x4 MWe MWM gas engines - Landfill gas
0.7 MWe Pescara, Italy Alma CIS/Fater (P&G Group) In operation since 2013 Electric power production from waste heat from 1x8 MWe Wärtsilä diesel engine
4.6 MWe Odayeri, Turkey Ortadoğu Enerji Under construction Electric power production from waste heat from 28x1.4 MW GE Jenbacher gas engines + 4x1.2 MW MWM gas engines - Landfill gas
2.3 MWe Komurcuoda, Turkey Ortadoğu Enerji Under construction Electric power production from waste heat from 12x1.4 MW GE Jenbacher gas engines - Landfill gas

TYPICAL APPLICATIONS

ORC size location customer status notes
1 MWe Rosetown, Canada TransGas In operation since 2011 Electric power production from waste heat from a 3.5 MW Solar gas turbine in a gas compressor station
1 MWe Andijan Region, Uzbekistan JSC "O'ztashqineftgaz" Under construction Electric power production from waste heat from a 3x15 MW GE gas turbines in a gas compressor station
5.5 MWe Shurtan, Kashkadarya Region, Uzbekistan SC “Uzneftegazdobycha” Under construction Electric power production from waste heat from a GE LM 2500 gas turbine in a gas compressor station

OUR EXPERIENCE

In 1996, Turboden realized its first heat recovery plant in an iron foundry in Brescia. Since then, Turboden has been involved in ORC projects in different industrial processes, such as cement industry, glass industry, steel industry, waste incineration, and mining. Turboden ORC units can produce electricity also by recovering heat from combined cycles, reciprocating engines, internal combustion engines, gas turbines, and gas compressor stations. In 2010, an innovative project was installed in Russia to recover heat, from the associated gas released from the process of oil extraction, through controlled combustion (instead of flaring). The plant generates both heat and power: the hot water is used to warm up the extracted oil while the electric power is used in the extraction station. The ORC turbogenerator produces 1,800 kW of electric power.

Another project was installed in Russia, in the Moscow region: this heat recovery ORC unit is coupled with five MTU engines, 2 MWe each. The exhaust gas of these engines is conveyed the ORC module by thermal oil.

Turboden was also awarded an order for a 4 MW ORC unit to recover heat in the cement industry in Slovakia. The plant produces 4 MW by recovering waste heat from the exhaust gas of the kiln and clinker cooler. The recovered heat is conveyed to the ORC by two different loops using thermal oil and water. This project represents another step of Turboden’s growth in the cement industry, coming after the successful startup of the 2 MW Ait Baha plant for Italcementi in December 2010. In February 2013, Turboden started-up its first application in the steel industry: a heat recovery system for power generation, in Singapore. The ORC is a 700 kW unit that recovers waste heat from a billet reheating furnace.

Furthermore, one of the latest innovative projects is a new 3 MW ORC unit that uses the heat from a portion of the saturated steam recovered from the exhaust gases of an EAF (Electric Arc Furnace), in Germany. This plant is part of the H-REII DEMO Project (Heat Recovery in Energy Intensive Industries), that the DG Environment of the European Commission decided to co-finance under the LIFE+ program for its technological innovation and environmental value.

  • TURBODEN WASTE HEAT RECOVERY APPLICATION IN CEMENT PRODUCTION PROCESS
  • TURBODEN WASTE HEAT RECOVERY APPLICATION FOR STEEL INDUSTRY
  • TURBODEN WASTE HEAT RECOVERY APPLICATION FROM INTERNAL COMBUSTION ENGINES

Waste Heat Recovery case histories