solution for renewable and green energy

BIOGAS STATIONSUtilization of waste heat and process heat from BGS with the use of the Green Machine

TECHNICAL SECTION

solution for renewable and green energy

What is the GREEN MACHINE?

The Green Machine works on the principle of ORC (Organic Rankine Cycle) for the utilization of waste heat which is converted into electrical energy.

The Green Machine unit by the ElectraTherm company produces fuel-free and emission-free electricity from process and waste heat already from 77 °C.

The Green Machine consists of a proven, patent-protected rotary twin screw expander. The Green Machine produces electricity, which is transformed from a source of low-temperature waste heat from BGS cogeneration units, and offers a very good return on investment.

solution for renewable and green energy

Green Machine UnitGreen Machine SERIES 4000 (electrical output from 20–65 kW)

Green Machine units can be connected in parallel, thereby producing a maximum output of 375 kW of electricity.

Electrical output* Conditions hot water Condensing conditions

kWeHot

Water°C

Thermal inputkW

Flow ratel/s

HotWater

°C

Ambient air temperature

°C

Condensation loadkW

20–65 77–116 400–860 3,8–12,6 4–43 < 38 380–795

Hot water to power* in metric unitsPERFORMANCE PARAMETERS

* gross production

solution for renewable and green energy

Working principle of the GREEN MACHINE

The system of conversion of heat into electrical current using the Green Machine works on the principles of a closed Organic Rankine Cycle (ORC). The principle is similar to a conventional steam engine, where boiling water is converted into steam, which is then transformed into mechanical energy. The Green Machine uses the unnecessary heat for heating-up the operating fluid to its boiling point and converts it into gas.

Steps in the process:

1 Heat is passed through the evaporator into the working fluid, heats the working fluid to boiling point and converts it into steam.

2 Steam enters in the screw expander, which converts the steam energy into mechanical energy.

3 Steam is further cooled by using a source of cold water in the condenser and condenses back into a liquid state.

4 The working fluid is pumped back into the evaporator. Then the cycle is repeated.

solution for renewable and green energy

Schematic diagram of the principle of the GREEN MACHINE function

3

3

2

2

1

1

4

4

pump

expander

generator

condenser

evaporator

Green Machinelow-pressure liquid

high-pressure liquid

heated pressurized steam

low-pressure steam

Heat input

Heat output

Electrical output

solution for renewable and green energy

Patented Screw ExpanderThe patented “twin screw expander” offers significant advantages

• Flue gases are not used, only hot water is used as a medium• High system efficiency at very low rotational speed <1800 rpm, as well as at the compressor• Lubricating system is contained within the working fluid

and no traditional lubricating system is needed• Low-speed and low-temperature operation• Transfer 3:1 with no gearbox or oil pump• Low operating costs• Simple design• Technology proven more than 15 years

The Green Machine represents a dramatic transition from the traditional ORC design type, based on the expansion of steam in a turbine, to screw expanders. It produces emission-free electricity from existing unused heat without adding any fuel.

solution for renewable and green energy

Standartized connection of CHP Jenbacher and Green Machine

94 kW

59 kW

75,0 °C 78,4 °C 88,5°C

98,6 °Cmax. 90 °C

max. 95 °C

50,0 °C 53,8 °C

55,0 °C

180 °C ~ 465 °C

90,7 °C 103,0 °C

281 kW 62 kW 341 kW

Oil Motor Mixture 1stphase

Hot water circuit (calculated with 37 % glycol)

Cooling circle(calculated with 37 % glycol)

Usable thermal outputProject J 316 GS-C25

Integration variant C

(±8 % tolerance * design reserve for re-cooling)

(±8 % tolerance * design reserve for re-cooling)

Hot water flow rate

Cooling water flow rate

778 kW

Heat output to be dissipated 59 kW

26,7 m3/h

15,0 m3/h

Mixture 2nd phase

Flue gas

solution for renewable and green energy

Standardized diagram of integration of the Green Machine

JMS 412 GS-B.L

Version B25

P el=889kW

P m=916kW

C

J I

D B

A

N

M

Vgas

Mz Hu

BIOGAS80-200mbar

≤ 1,

3m

H

MAX. ΔT 10°C/MIN

MAX. ...BAR MIN. 2,5BAR

Qww

B

AC

Qgk2

FF

LpMaf

Qag

P.01-YCI-101

P.01-YFA-101P.01-F-102

P.01-YCS-101P.01-F-101

P.06-YPS-001

P.06-YFC-003

P.06-YTC-001P.06-M-001

P.06-P-001P.0

6-B-

001

P.06-YPC-001

P.06-

W-1

01

...×

...kW

...A

...V

...Hz

P.06-W-001

P.06-YTC-002

P.07-

YPS-

001

P.07-B-001

P.07-YPC-001

P.07-P-001P.07-M-001

P.07-W-002

...×

...kW

...A

...V

...Hz

P.07-

YTC-

001

DN

125

/ DN

100

DN125 / DN100

P.02-W-001P.02-XSA-001

...×

...kW

...A

...V

...Hz

ORC

ARI-E

URO-

WED

I-DN8

0

DN100

DN100

2,5 bar

DN 80

DN 80

PITI

TI

80 l

G1/24 x DN 65

PN10DM28

PN10DM28

[..-..]

[01]

[..-..]

Δp MN = 0,8bar MAX.

150mbar

AH

SL DN125

PN16

JES

DN125PN16

PN16DN125

PN10DN100

PN10DN100

.bar

103,

0°C

80,0°C

...kW

.A

...V

...Hz

80,0°C

75°C

..bar

75,0°C

85,0°C

Δp=

.bar

74°C

.bar...bar

..bar

...

...

AHAL

...kW

.A

...V

...Hz

PN10DN65

55,0°C

PN10DN65

58,1°C

55,0

°C44-54°C

DN300PN10

650°C

AH

JES

JES

JES

JES

99°C

ASH

ASH

5bar

ASH

2,5bar

ASL

JES

JES

JES

JES

JES

93,2°C

90,0°C

180°C

AH

JES

424°

C

58,1°C

Δp=

.bar

Δp= .bar

JES

.Sh

eet .

. Shee

t .

. Shee

t .

.Sheet .

III

III.Sheet . III

.Sheet .

.Sheet .

. Shee

t ..Sh

eet .

JES

JES

JES

JES

JES

JES

JES

JES

JESJES

PS

P.01.103

US

P.01.101

PDS

...

PS

P.01.101

PI

P.01.101

PI

P.01.102

TI

P.01.103

PI

P.06.002

PI

P.06.001 NC

P.06.001

TC

P.06.012

TI

P.06.012

PI

P.06.005

TC

P.06.015TI

P.06.015

PI

P.07.001

PS

P.07.001

NS

P.07.001

PI

P.07.002

PI

P.07.003

TI

P.02.008

PS

P.06.001

TS

P.06.001PI

P.06.006

TS

P.06.023

PS

P.06.030

PS

P.06.045

TI

P.02.008

YCZ

P.01.103

YCI

P.01.103

YCZ

P.01.110

. L

... L

. L

solution for renewable and green energy

Technical priorities of the Green MachinePriorities and advantages • Flue gases are not used, only hot water is used as a medium

• Modular and scalable design (outdoor version)

• Automated system of control and inspection

• Easy integration into the hydraulic circuit of warm (hot) water CHP

• Simple installation (max. 4 days to launch)

• Contains only three main components with moving parts

• Cooling by the use of air or water

• Production of electrical energy without a combustion process

• No toxic combustion products

• Remote control and monitoring

• Automatic Start / Stop system

The Green Machine transforms between 9,5–11% of low-temperature thermal energy, depending on the condensing temperature, to electricity.

PLC panel Green Machineremote monitoring+ control

solution for renewable and green energy

Why to connect the Green Machine

Electricity produced from the Green Machine:

• is used to cover the technological self-consumption of a given biogas station (BGS)

• is used to cover the technological self-consumption of a given cogeneration unit (CHP)

• is used to cover self-consumption by the premises of a biogas station (BGS)

• is possibly used for sale into the grid

REFERENCES FOR THE GREEN MACHINE

solution for renewable and green energy

Basic information about installation of the Green Machine

Location:BGS Moravská TřebováCzech Republic

1 pc Green Machine < 50 kWoperating hours > 9200 hours

Cogeneration unit: MWM – 2 × 499 kW

Disposable heat: < 450 kW

Input temperature reached: 90 °C

Average output of Green Machine: 36 kW

solution for renewable and green energy

Basic information about installation of the Green Machine

Investor:Fosfa, a. s.Břeclav-Poštorná, Czech RepublicCogeneration unit for burning natural gas

2 pc Green Machine < 50 kW

Cogeneration unit: Tedom 2 × 500 kW

Disposable heat: < 800 kW

Input temperature reached: 92 °C

Average output of Green Machine: 76 kW

solution for renewable and green energy

Basic information about installation of the Green Machine

Location:BGS Vysoké MýtoCzech Republic

1 pc Green Machine < 50 kW

Cogeneration unit: Schnell 4 × 250 kW

Disposable heat: < 650 kW

Input temperature reached: 95 °C

Average output of Green Machine: 39 kW

solution for renewable and green energy

Basic information about installation of the Green Machine

Location:BGS BrnoCzech Republic

1 pc Green Machine < 50 kW

Cogeneration unit: Schnell 4 × 250 kW

Disposable heat: < 600 kW

Input temperature reached: 95 °C

Average output of Green Machine: 39 kW

solution for renewable and green energy

Basic information about installation of the Green Machine

Location:BGS Zemplínská TeplicaSlovak Republic

1 pc Green Machine < 65 kW

Cogeneration unit: Jenbacher 1036 kW

Disposable heat: < 780 kW

Input temperature reached: 115 °C

Average output of Green Machine: 55 kW

solution for renewable and green energy

Basic information about installation of the Green Machine

Location:BGS StrážniceCzech Republic

1 pc Green Machine < 50 kW

Cogeneration unit: Jenbacher 889 kW

Disposable heat: < 550 kW

Input temperature reached: 100 °C

Average output of Green Machine: 41 kW

solution for renewable and green energy

Basic information about installation of the Green Machine

Location:BGS ŠlapanovCzech Republic

1 pc Green Machine < 50 kW

Cogeneration unit: Jenbacher 750 kW

Disposable heat: < 550 kW

Input temperature reached: 100 °C

Average output of Green Machine: 41 kW

solution for renewable and green energy

Basic information about installation of the Green Machine

Location:BGS TrechwitzGermany

Cogeneration unit: MWM 1000 kW

Disposable heat: < 450 kW

Input temperature reached: 95 °C

Average output of Green Machine: 37 kW

solution for renewable and green energy

Basic information about installation of the Green Machine

Location:BGS BohmteGermany

Cogeneration unit: Jenbacher 800 kW

Disposable heat: < 500 kW

Input temperature reached: 90 °C

Average output of Green Machine: 32 kW

in connection with the operation of theGreen Machine at BGS and CHP

ECONOMIC BENEFITSOF THE GREENMACHINE

solution for renewable and green energy

Control measurement of hourly output and efficiency of CHP

Location: Strážnice, Czech Republic

BGS parameters:

Installed capacity of CHP: 889 kW

Design parameters of the Green Machine:

1 pc Green Machine – performance series 50 kW

Operating hours: > 3.060 hours

Cogeneration unit: Jenbacher – 889 kWe

Disposable heat: < 600 kWt

Input temperature reached: 94–96 °C

Average output of Green Machine: 38–43 kW

BGS Strážnice – test of hourly output and efficiency of CHP with and without the Green Machine

solution for renewable and green energy

Test carried out on 27/02/2013, CHP – Jenbacher, ambient temperature 4–6°C

Installedcapacity of

CHP

Efficiency of CHP

(%)

889 kW 100,00

CHP – productionof electricity withoutthe Green Machine

Efficiencyof CHP

(%)

823,2 kW 92,6

CHP – productionof electricity

without the Green Machine

Efficiency of CHP

(%)

872,4 kW 98,1

Increase in efficiency of CHP

(%)

5,5

The electricity supply to the grid (kW)

without installation of the Green Machine without installation of the Green Machinewith installation of the Green Machine with installation of the Green Machine

Increase in the efficiency of CHP (%)

solution for renewable and green energy

BGS Strážnice – output of CHP (excerpt from the basic technical conditions)

Technical description of CHP – Jenbacher JMS 412 GS-B.L

Standardized referential conditions:Air pressure 1000 mbar or 100 m a.s.lAir temperature 25 °C or 298 KRelative humidity 30 %

Volumetric data in the normal state (combustion gas, combustion air and flue gas):pressure of 1013 mbartemperature 0 °C or 273 K

According to technical conditions, the total output with tolerance ± 8 %

The decrease in engine power for turbocharged engines::In the case of the motor installed at an altitude of ≤ 500 m and at air temperature ≤ 30 °C (T1)Maximum temperature of engine room: 50 °C (T2) failure that causes stoppage

RETURN PAYBACKOF INVESTMENTS

a model casenew installations at BGS

solution for renewable and green energy

A model example of the potential for installing the Green MachineBGS – 1000 kWe, 1000 kWt

(40% of the heat is used for BGS technology, 60% for the Green Machine)

Table of assumed values

Amount of heat for the Green Machine 600 kWt*

Available temperature of medium on inlet 95 °C

Hot water flow rate 10 l/s

Number of operating hours of Green Machine and CHP (assumption) 8200

The calculation of revenues and payback of investment is based on real paramenters of waste heat and of process heat and on the options of the investor

* The Green Machine can already be installed from 300 kWt

solution for renewable and green energy

Approximate self-consumption of devices

Green Machine Cogeneration unit

Internal pump Green Machine 1,5 kW Pump of CHP cooling 4,5 kW

Green Machine cooler 6 kWCHP coolers(the average electricity consumption)

12 kW

Total maximum consumption above 29 °C 7,5 kW Total maximum consumption above 29 °C 16,5 kW

Consumption at the average temperaturin Germany

5 kWConsumption at the average temperaturein Germany

19,5 kW

Benefit of Green Machine for improving the efficiency of CHP (reducing self-consumption)

Savings in CHP cooling – increase in the efficiency per hour of operation(minimum temperature reached)

4,5

Total savings per year 36 900 kW

Primary benefit in reducing the self-consumption from cooling of engine CHP

ELECTRICAL OUTPUTAND REVENUES

an example casenew installations at BGS

solution for renewable and green energy

A model example of assumed electrical outputs of the Green Machine

Table of assumed values

Available amount of heat – the average output of unit 600 kWt

Temperature of medium at the input to Green Machine 95 °C

Gross produced electricity per hour 43 kW

Net electricity generation per hour (after deducting the internal consumption of Green Machine) 41 kW

Number of operating hours of Green Machine and CHP (assumption) 8200

Net electricity generation per day (24 hours) in Green Machine 984 kW

Net electricity generation per year in Green Machine 336 200 kW

Savings in cooling of CHP per year (see the self-consumption in cooling of CHP) 36 900 kW

The total energy per year for sale / self-consumption 373 100 kW

Prerequisites of an increase in efficiency of CHP per hour in energy production through installing Green Machine 30 kW

Prerequisites of an increase in efficiency of CHP per year in energy production through installing Green Machine 246 000 kW

Assumed production of Green Machine with an increased efficiency of CHP 619 100 KW

solution for renewable and green energy

Simple return on investment in the production of electricity

Production of electricity from Green Machine per year 373 100 kW

Prerequisites of an increase in CHP efficiency per year of energy production through the installation of Green Machine

246 000 kW

Assumed production of Green Machine with increased efficiency of CHP 619 100 KW

Coverage of BGS self-consumption within the buy-out prices 0,170 EUR/kWh

Economic benefit (total revenue per year) 105 247 EUR

Economic benefit (revenue in total per 20 years of service life and operation of Green Machine) 2 104 940 EUR

Total cost of installing a turnkey Green Machine 290 000 EUR

Simple payback of Green Machine 2,75 years

SERVIS PLAN FOR THE GREEN MACHINE

standard service operations

solution for renewable and green energy

Two-year plan of servicing operations for the Green Machine1st year – hours of operation 2nd year – hours of operation

2200 4400 6600 8800 11000 13200 15400 17600

Check of the drive belt tension x x x x x x x x

Inspection of pipe routes, flanges, valves whether or not they show signs of leak x x x x x x x x

Check technical elements (wear, damage) x x x x x x x x

Lubrication of pump for working fluid x x x x x x x x

Replacement of belt x x x x

Inspection of bearings in generator (smooth run of shaft) x x x x

Cleaning of filters in control panel, checking the run of ventilators x x x x

Check of cabling (wear, damage) x x x x

Lubrication of bearings in generator x x x x

Control of the pressure losses on the side of hot water x x

Test of acidity of refrigerant x x

Cleaning of Green Machine cabinet x x

Checking the oil concentration in the refrigerant x x

Checking the function of compressed air system x x

Checking of safety devices (light indication, buttons, labels) x x

Replacement of relief valves x

Replacement of batteries in display and PLC x

Plan of servicing operations for the Green Machine

By installing Green Machine technology by the ElectraTherm company, you will convert process heat from the cogeneration unit to electricity without the need for fuel..

THIS IS SMART POWER™