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Turboden
Overview
Turboden is an Italian firm and a global leader in the design, manufacture and maintenance of Organic Rankine Cycle (ORC) systems, highly suitable for distributed generation, that generate electric and thermal power exploiting multiple sources, such as renewables (biomass, geothermal energy, solar energy), traditional fuels and waste heat from industrial processes, waste incinerators, engines or gas turbines
Korra Energi, as the representatives of Turboden in Egypt, have presented the ORC (Organic Rankin Cycle) in Egypt. ORC technology is “The cleaner & efficient alternative for distributed power generation” which turns waste-heat into useful power.
Turboden’s strong track record covers more than 455 ORC plants in 52 countries. They have the largest market share worldwide of 73% for waste heat recovery for power generation using ORC.
The organic Rankine cycle (ORC)
- ORC transfers heat contained in the preheater tower (PH) and clinker cooler (CC) hot gas streams through an intermediate fluid (eg, thermal oil). Unlike the conventional Steam Rankin Cycle (SRC) technology, ORC units use organic fluids such as hydrocarbons, silicon fluids or refrigerants depending on the size of the ORC and temperature level. The most frequently used organic fluid for cement heat recovery is cyclopentane.
- ORC technology does not consume any water. In fact, the condensing heat is dissipated directly into the air utilizing air-cooled condensers without negatively impacting performance. This is a key consideration in regions such as the Middle East, where water is a scarce and precious resource.In terms of management efficiency, ORC systems do not require supervisory personnel during normal operating conditions or shutdown procedures.
- ORC is a fully automatic system, designed to self-adjust to operating conditions. Variations on exhaust gas temperatures and flows will not affect functionality of the system. Furthermore, partial load efficiency is much higher compared to steam turbines and the ORC functions at 10 per cent of nominal load. Its efficient use of medium- to low temperature thermal sources enables energy availability greater than 98 per cent.
Minimal Operation and maintenance cost
Water free system
No Major Overhaul
High Flexibility
Wide Operation Range 10 to 110%
> 98% Availability
ORC as a Waste Heat Recovery (WHR) solution
is becoming popular in high energy intense industries such as cement.
The benefits of Waste Heat Recovery are also connected to the importance of being less dependent on volatile energy prices, where the ability to produce energy using a waste heat source guarantees a stable price of electricity (which can amount to 30% of a cement plant’s needs).
Dahshour’s “First of its kind” Waste Heat Recovery -Cogeneration System
We are proud of Dahshour’s “First of its kind” Waste Heat Recovery-Cogeneration System through a 28MWe Organic Rankine Cycle (ORC). Dahshour Plant is a key project for Korra Energi as the representative of Turboden in Egypt supplying the largest high temperature ORC system ever built in the world, this will boost the sustainability of natural gas transportation infrastructure and the energy transition for the industry.
