The hot-water ORC

For more information, please
contact us

Lubomír Sovíček
Email: lubomir.sovicek@bpower.cz
Phone: +420 734 576 035

The hot-water ORC uses, if possible, the highest possible potential of residual heat
from the cogeneration unit. However, not by connection to flue gases, but – if possible
– to the whole hot-water circuit of the engine. The hot-water ORC is suitable for the
connection to the engines already from 500 kW of electric output.

Single Heat Stream

We can view the hot-water ORC in connection with the cogeneration unit engine as a very effective cooler.
ORC is connected as a consumer of hot water from the cogeneration unit.
It means that water from the cogeneration unit cooling enters the flue gas heater exchanger and from there to the entry to the ORC system – the so-called Single heat stream.
Via the ORC exchanger, then cooled water returns back to the engine circuit.

Another possibility how to connect ORC to the cogeneration unit engine is the so-called pairing with the engine refrigeration circuit. It is the principle of using the ORC refrigeration circuit for additional cooling of the reverse branch of cooling water of the engine. The reason for using is simple – complete shutdown of the engine cooling and high savings of financial means in the own consumption of the refrigeration circuit of the engine. At the same time, the whole concept is completely safe – in the case of ORC shutdown, the whole cooling system is still in operation and the engine is not at risk of insufficient cooling.

The whole concept is shown in the following picture:

Advantages of the hot-water ORC:

As a medium for ORC, you can use how water already from 77 °C
Very simple connection to the existing system of the cogeneration unit
Low operating costs and simple maintenance

Thanks to the fact that our company has both ORC technologies, our team is ready to help you find and possibly suitably interconnect these technologies so that the effect of use of heat from the engine of the cogeneration unit is the highest possible.

WE OFFER THESE PRODUCTS

Technology ElectraTherm

ORC POWER+ PM75, 6500B, 6500B+

The Power+ units are able to use heat sources from 70 ° C and generate up to 125 kWe.

The Power+ generator using organic Rankine cycle together with patented technologies -
double helix, converts sources of low-temperature heat and waste heat into electricity
without additional fuel consumption or emissions. Heat sources with a higher temperature higher than 150 ° C - for example thermal oils and exhaust gases can be used with the use of an additional heat exchanger.

Technologie Power+ PM75

Bitzer expander, double helix patent

Technology SMART POWER ORC

Thanks to the integration of the BITZER semi-hermetic expander, ElectraTherm's ORC solutions represent a dramatic shift away from turbine technologies. The expander not only provides a more cost-effective and robust design that significantly increases reliability, but also has much lower operating speeds that allow for "wet" two-phase flow.

As a result, the expander is better equipped for transient operation, which allows the system to reliably generate energy from heat sources with temperature and flow fluctuations. ORC systems from ElectraTherm based expander are more ideal for variable heat sources with lower temperature compared to turbine based systems.

The new expander from the parent company ElectraTherm - BITZER ensures smooth operation and absolute reliability.

POWER+ PM75 is a smaller series ideal for heat output up to 1250 kWth. Generates up to 75 kWe.

POWER+ 6500 / 6500B+ - is a larger range ideal for heat output up to 2,200 kWth. Generates up to 125 kWe.

Capacity parameters

			PM75	6500B	6500B+
device capacity	output power	kWe	až do 75	až do 125	až do 125
heat source conditions	thermal input	kWth	300 - 1250	400 - 1700	400 - 2200
	hot water temperature	°C	65 - 132	70 - 132	70 - 150
	hot water flow rate	l/s	3 - 23	3 - 25	3 - 25
condensing conditions	heat rejected	kWth	300 - 1200	400 - 1600	400 - 2000
	cold water temperature	°C	10 - 65	4 - 65	4 - 65
	cold water flow rate	l/s	6 - 26	9 - 26	9- 26

* Heat sources with a temperature higher than 150 ° C - such as thermal oils and exhaust gases - can be used using another heat exchanger.

Process

Heat enters the evaporator and heats ORC operating fluid (refrigerant) to the boiling point and thus it is converted into steam.
The hot steam creates pressure.
The steam is forced through the screw expander and spins an electric generator.
Steam is cooled with a source of cold water and condenses back to liquid form in the condenser.
Operating fluid is pumped to a higher pressure, it returns back into the evaporator and the process repeats.

Technical specifications

	Construction
	Installing refrigerant	built according to standards ASME and CE
	Energy block	patented twin screw expander
	Generator	asynchronous
	Heat exchanger	compact, brazed board construction
	Lifespan	20 years

	System description
	Operating fluid	pentafluoropropane (nonflammable, nontoxic, not harming the ozone layer)
	Heat source	hot water from 70°C to 150°C flue gas from 150 °C
	Cooling requirements	water temperature 4°C to 65°C
	Control	common management software / standard programable logic controller
	Remote monitoring	internet
	Operation	designed for unattended operation
	Sound pressure level	80 db at 1 m; optional silence; <72 db at 1 m

Possible configurations of POWER+ DEVICE

Freestanding

20 ft. ISO frame

40 ft. ISO frame

Dimensions: 2,4 x 2 x 2,3 m

Dimensions: 6,1 x 2,4 x 2,6 m

Dimensions: 12 x 2,4 x 2,6 m

Indoor and outdoor installation

Possibility of modular wiring
Easy installation without a concrete foundation
Integrated mounting with a dry cooler

Turnkey installation including a cooling circuit piping and pump
Without a conceret foundation
Plug&play

Advantages of the POWER+ series

Automated management system
Low maintenance requirements
Modularity and scalability
Robust twin screw expander
CE certification
Zero emissions
No secondary toxic products
Zero consumption of fossiel fuel
Remote monitoring

Utilizing the technologies:

Natural gas engine
Petrol and diesel engines
Biomass engines
Biogas
Boilers
Heat from industrial processes
Solar heat
Geothermal energy

For more information, visit www.electratherm.com - Power+ generátor

For more information, please
contact us

Lubomír Sovíček
Email: lubomir.sovicek@bpower.cz
Phone: +420 734 576 035

PM75 6500

Technology ORCAN

The ORCAN technologies focus on a wide range of the ORC systems, from the smallest ones (5 kW) up to bigger ORC systems producing 300 kW of electricity. Another flagship of this company includes zero energy consumption coolers - ORCAN cooler.

Tens of installations of these units all over Europe are evidence of first-rate quality of German technology. The supplier of expanders for ORC is the company Bitzer – the world number one in the field of producers of compressors.

ORC system efficiency PACK NT:

Our solution for low temperatures: at the input output from 180 kWth the installation of the equipment efficiency PACK NT is ready in several simple steps. It integrates efficiency PACK NT in the best place of your system. The equipment efficiency PACKNT has an integrated pump for volume discharge flow between 10 and 18 m3 / h.

Temperature of water at input [°C]	Temperature of heat water at output [°C]	Volume discharge [m³/h]	Quantity of heat [kW_th]	Net output [kW_el]	Gross output [kW_el]
80	69	14	177	5,9	7,9
85	73	14	199	7,3	9,3
90	76	14	221	8,7	10,7
95	80	14	243	10,1	12,1
100	84	14	266	11,6	13,6
105	87	14	289	13,1	15,0
At ambient temperature of 10 ˚C, output data +/- 8%

ORC system efficiency PACK 150.200

This ORC series is suitable for using hot water of the temperature of 80 – 145 ˚C and the volume flow of 11 – 14 m3/h or water steam of the temperature of 150 - 800 ˚C. With the maximal input heat of the output of 500 kWth, the ORC is able to produce up to 30 kW of electricity.

efficiency PACK 150.200

ORC system efficiency PACK 050.100

It can use residual heat of engines with the output of 1 – 20 MW with efficiency of 7%. Heat can be taken directly from flue gases (max. 550 ˚C) or from hot water of the maximal temperature of 150 ˚C. This system is able to produce up to 100 kW of electric energy.

efficiency PACK 050.100

For more information, please
contact us

Lubomír Sovíček
Email: lubomir.sovicek@bpower.cz
Phone: +420 734 576 035

Technology ORCAN cooler

The ORCAN technologies focus on a wide range of the ORC systems, from the smallest ones (5 kW) up to bigger ORC systems producing 300 kW of electricity. Another flagship of this company includes zero energy consumption coolers - ORCAN cooler

ORCAN cooler – the cooler of the new generation with zero electric energy consumption:

The built-in ORC module (Organic-Rankin-Cycle) converts waste heat into electricity that is used for the cooling system operation. In the engine of the output of 500 kW it can save up to 8 kW/h.

ORCAN cooler solves the following problems with the cooling of cogeneration units:

The fact that the current cooling is undersized forces to limit the output in the summer months = loss of sales
Older coolers lose their cooling effectiveness and are often liable to failure = increased operating costs
Due to the engine overheating, oil is often exchanged = increased service costs

The cooler is delivered in the horizontal version in the three basic series – 400 kWth, 600 kWth and 800 kWth. When the so-called double cooler is selected, both engine circuits (LT and HT) are cooled down simultaneously.

Suitable for input temperature in the cooler from 60˚C
Waste heat with output more than 125 kWth
At ambient temperatures up to 30˚ C with the minimal/zero electricity consumption
It is not a source of the production of electric energy
Fast return on investment

ORCAN cooler has the best output-price ratio in comparison with the standard coolers:

	Low-cost cooler	Effective cooler	ORCAN cooler
Low CAPEX	*******	**	**
Low OPEX	*	**	*******
Total costs	*	**	*******