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International Nordic Bioenergy 2003 conference • Screw-type engine process • ORC process • Gas turbine processes • Stirling engine process Fixed-bed gasification processes also represent a future potential for small-scale biomass CHP plants but have not yet achieved a level of development which allows commercial application. Depending on the amount of full-load operating hours, the size of the CHP plant and the biomass fuel price, small-scale biomass-fired CHP plants can produce electricity at costs between 70 and 150 €/MWhel (no investment subsidies considered). The steam processes and the ORC process are presently the best developed and the most economical systems available. The most important influencing variable on electricity production costs are the annual full load operating hours of the CHP plant. For economic operation a minimum value of 5,000 hours can be recommended which shows the importance of an optimal "sizing" of the CHP unit according to the annual heat output line. 3 ORC PROCESS 3.1 Description of technology The principle of electricity generation by means of an ORC process corresponds to the conventional Rankine process. The substantial difference is that instead of water an organic working medium with favourable thermodynamic properties is used [1,2,3]. The working principle and the different components of the ORC process are shown in Figure 1. The ORC process is connected with the thermal oil boiler via a thermal oil cycle. The ORC unit itself operates as a completely closed process utilising a silicon oil as organic working medium. This pressurised organic working medium is vaporised and slightly superheated by the thermal oil in the evaporator and then expanded in an axial turbine which is directly connected to an asynchronous generator (see Figure 1). Subsequently, the expanded silicon oil passes through a regenerator (where in-cycle heat recuperation takes place) before it enters the condenser. The condensation of the working medium takes place at a temperature level which allows the heat recovered to be utilised as district or process heat (hot water feed temperature about 80 to 100°C). The liquid working medium then passes the feed pumps to again achieve the appropriate pressure level of the hot end of the cycle. In order to obtain a high electric efficiency (= net electric power produced / thermal power input) of the ORC unit itself, it is necessary to keep the back-pressure of the turbine as low as possible and thus to minimise the necessary temperature for district heat utilisation at the condenser of the ORC plant (approximately 80 °C feed water temperature). This can be achieved by optimising the operation and control of the district heating network in order to keep the necessary feed-water temperature as low as possible as well as by an optimised hydraulic integration of the ORC in the district heating network. In order to achieve this goal, the ORC should be directly connected to the return of the district heating network and the feed water temperature at the ORC outlet should be kept as low as possible by placing the hot water economiser and the hot water boiler downstream of the ORC (see section 3.2, Figure 2 and Figure 3). Following this approach, the ORC can be operated at feed-water temperatures of about 80°C the whole year round, although the feed-water temperature required for the district heating network amounts to 90 to 95 °C in winter. ORC plants are relatively silent (the highest noise emissions occur at the encapsulated generator and amount to about 85 dB(A) at a distance of 1 m. Figure 1. View of an ORC plant. Source: TURBODEN Srl, Brescia, Italy. Since the cycle of the ORC process is closed and thus no losses of the working medium are possible, the operating costs are low. Only moderate consumption-based costs (lubricants) and maintenance costs are incurred. The usual lifetime of ORC units is greater than twenty years, as has been proven by geothermal applications. The silicone oil used as working medium has the same lifetime as the ORC since it does not undergo any relevant ageing. 3.2 EU demonstration project Lienz with optimised ORC process integration The biomass CHP plant in Lienz is located in East Tyrol, Austria, and supplies the town of Lienz with district heat (see Figure 2) [4]. It started operation in autumn 2001 and will cover the heat requirement of approximately 70 % of all buildings in the supply area by the end of 2003. The residential and industrial heating systems replaced are mainly oil-fired boilers which results in a considerable CO2 reduction. Thermal and electric output of the CHP plant [kW] 25,000 20,000 15,000 10,000 5,000 0 Solar thermal collector Peak load boiler Heat recovery Hot water boiler CHP unit Electricity production 0 1,200 2,400 3,600 4,800 6,000 7,200 8,400 operating hours per year [h] Figure 2. Annual heat and electricity output line for the final stage of development of the district heating network – biomass CHP plant in Lienz Figure 2 shows the annual heat and electricity output line for the biomass CHP plant in Lienz. The thermal oilPDF Image | FUTURE DEVELOPMENTS REGARDING SMALL-SCALE BIOMASS CHP
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