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MARKET POTENTIAL STUDY FOR ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA The Stadtwerke Groß-Gerau Versorgungs-GmbH (GGV) municipal utility company has invested in an energy-efficient Organic Rankine Cycle (ORC) system from Dürr Cyplan, and thereby increased the power to heat ratio of its cogeneration units (Combined Heat and Power or CHP). Since the end of 2007, the biogas system of this municipal utility company has been converting biomass to biogas in order to fire two CHP units. The Dürr ORC system, integrated in November 2012, increases the efficiency of electricity generation and improves the heat utilization concept. So far, the two CHP units have produced 8.3 million kilowatt-hours of electricity per year, providing power to around 7,100 end-users. The heat produced in the process is used to heat the municipal utility company’s buildings and also those of the neighbouring companies. Additionally, the fermenter and post- fermenter are also heated. The temperatures are maintained at a constant level of 40 degrees Celsius (40°C) to ensure ideal living conditions for the microbes responsible for the fermentation and outgassing processes. During the summer, the heat is also used to dry herbs in a neighbouring agricultural operation. “The concept, thus, corresponds to the fundamental idea of combined heat and power (CHP), according to which the energy is simultaneously converted to electrical power and heat and used,” says GGV Managing Director Paul Weber. DÜrr orc tEchnology The integration of the ORC system from Dürr, the system construction specialist, enhances comprehensive the energy utilization. ORC stands for “Organic Rankine Cycle” – a procedure that uses waste heat to produce electricity with the aid of an evaporation process. In Groß-Gerau, the high- temperature flue gas waste heat from a CHP unit with an electrical output of 800 kWe is used for this purpose. “This proven principle produces 60 kWe of additional power on average,” explains Dürr project leader Timm Greschner. “No heat is lost in the process, no matter whether or not a concept for heat utilization exists. Up to 18% of the total heat in the flue gas is converted to electricity, and the remaining (approx. 82%) is provided at a temperature level of up to 90oC.” A significant efficiency increase in power generation has, therefore, been realized in Groß- Gerau without restricting the existing heat utilization concept. figure 23: orc system in groß-gerau Photo by Dürr Cyplan Ltd. The ORC system is simple, robust and easily integrated into the overall system. Since there is no complex intermediate circuit and no separate turbine lubrication with lubricating oil, the system operation is also very stable. The ORC system uses the flue-gas heat throughout the year and also produces full power in the summer, thanks to the high condensation level. Economic EfficiEncy This investment has been worthwhile for the Stadtwerke Groß-Gerau municipal utility company. The integration of the ORC system permitted the exhaust-air heat exchanger behind the CHP unit to be omitted. The total electrical power generated is increased from 8.3 to more than 8.7 million kWh. This allows electricity to be provided to around 360 or more end-users. Despite the omission of the exhaust-air heat exchanger, the heat is fed into the heating network and is fully available for herb drying and for heating the administration building, the fermenter and the post-fermenter. The amortization period of such an ORC investment is five years with an electricity buyback price of 20.3 Euro cents/kWh and 7,500 hours of full utilization. With a depreciation period of ten years, this corresponds to an internal rate of return of 15.6%. The use of ORC technology perceptibly increases the CHP remuneration. According to the recommendation from the clearing office for the German Renewable Energy Law dated 40PDF Image | ORGANIC RANKINE CYCLE TECHNOLOGY IN INDIA
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