xx/xx/2017 pitagoras project · pdf file-20% cut in greenhouse gas emissions 1 ... the new...

PITAGORAS project

XX/XX/2017

General overview and main results

Sustainable urban Planning with Innovative and low energy Thermal And power Generation frOm Residual And renewable Sources

To demonstrate highly replicable, cost-effective and high energy efficiency large scale energy generation systems that will allow sustainable urban planning of very low energy city districts.

Overall GOAL:

“Efficient integration of industrial parks into city districts through smart thermal grids”.

INDUSTRY: from energy CONSUMER to energy SUPPLIER

FRAMEWORK AND SCOPE01

FRAMEWORK AND SCOPE 01

Cities: - Responsible for about 70% of the overall primary energy consumption- This share is expected to increase to 75% by 2030 (IEA, 2008c).

The path set by EU policies is clear:

In order to achieve those goals, development of low energy solutions for thermal energy supply to cities is one of the main needs of our society.

Industries: - Responsible for wasting large amounts of valuable energy. - A 40% of the consumed energy in industries is lost as waste heat.- Thus, one of the sources with the highest potential nowadays is the recovery of waste heat.

______________________1 Compared to 1990 levels.2 Compared with the business-as-usual scenario.

Energy scene and policies

Targets for 2020:

- 20% cut in greenhouse gas emissions1

- 20% increase of energy savings- 20% minimum share of renewables2

Targets for 2030:

- 40% cut in greenhouse gas emissions1

- 27% increase of energy savings- 27% minimum share of renewables2


Waste heat recovery

European industry generates annually approximately 4.000 TWhof waste heat, which is equivalent to the incident solar radiation in 3.300.000 km2 (approx.1/3 of the total area of Europe).

Assuming that 50% of total available waste heat can be recovered would imply a potential of 2.000 TWh of useful heat per year.

This amount of energy is equivalent to 17.000 million m3 of natural gas.

The use of this amount of waste heat for heating, cooling and power generation would entail saving more than 2.000TWh of fossil fuels, that is, a reduction in GHG emissions of about 4.500 million ton CO2/year.

Main industrial centres in Europe. Source: www.mapsofworld.com

Main metal processing centres in Europe. Source: www.mapsofworld.com


Goals

PITAGORAS aims at the efficient integration of industrial parks into city districts through smart thermal grids.

Technologies and concepts are developed on two fields:

1) Medium temperature industrial waste heat recovery2) Integration of renewable energy sources (RES)

Both aiming at the same target:

- Integration of sustainable energy sources into the networks supplying heat (and power) to cities.

INDUSTRY:

BEFORENet energy consumer

AFTERConsumer + Producer


The main breakthrough of the project is the overall system integration and optimization.

All the technologies considered in the project are proven technologies; the focus is not on technological developments but integration:

overall system conception.


Involved systems and concepts

> Waste heat recovery system

> Organic Rankine Cycle

> Seasonal thermal energy storage

> Solar thermal energy

> Integration of new technologies, concepts and systems developed and state-of-the-art systems

> Innovative tools for efficient energy management

Construction of a Seasonal Thermal EnergyStorage of 5700 m3 in Munich. Source: Solites

Roof mounted solar thermal collectors. Source: Solid


Pitagoras consortium

Project Coordinator

PITAGORAS Project, co-funded by the European Commission, is framed into FP7-Smart Cities Programme

The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant agreement n° ENER / FP7EN / 314596 / PITAGORAS. This publication reflects only the author’s views and the Union is not liable for any use that may be made of the information contained therein.

PITAGORAS PLANTSIntroduction

02

PITAGORAS PLANTS 02

Pitagoras plants

1) Brescia (Italy): • Industrial waste heat recovery in a Steel Mill• Recovered heat is used for power generation and district heat supply

2) Kremsmünster (Austria):• Integration of a large scale solar thermal plant into an oil and gas industrial area• Use of solar thermal energy, in combination with a large seasonal thermal energy storage (STES), as

heat supply for the local DH network and process heat

Current status

1) Brescia (Italy): • Built and started up in 2016• Currently undergoing a monitoring and optimization campaign

2) Kremsmünster (Austria):• Design phase completed • Heat supply contract negotiated between the ESCO and the client• Implementation postponed

(WtE)

(CHP & gas boilers)

(gas boilers)

PITAGORAS PLANTS - Brescia 02

Brescia – context and framework

• The first Italian city developing a DH system (in the 1970’s), driven by the will of the municipality

• Heat supply to 21.000 buildings, 70% of the heat demand of the city:

- Installed capacity2015: 710 MW

- Heat consumption2015: 1.266 GWh/y

- Total length: 663 km

• Energy sources of the net (2015):

- 180 MW waste-to-energy

- 110 MW multi-fuel CHP (coal and gas)

- 420 MW natural gas boilers

• Evolution of the energy mix of the city of Brescia:

- From 100% fossil fuels in the 1950’s to 40% WtE

- DH deployment played a key role on achieving it

- Still potential (and willingness) to reduce the carbon footprint of the net


Brescia – ORI MARTIN steel mill

• ≈9MW of industrial waste heat available for recovery• Located very close to urban areas

(WtE)

(CHP & gas boilers)

(gas boilers)

ORI MARTIN steel mill


Brescia – Waste heat revalorization plant

Waste heat is recovered from the electric arc furnace (EAF) exhaust gas outlet, generating saturated steam. The steam carries the recovered heat, which is used for power generation and district heat supply


Demonstration plant consisting of the waste heat recovery unit, a steam accumulator (in order to

smooth the steam supply), and ORC module and the district heating substation

PITAGORAS PLANTS - Kremsmünster 02

Kremsmünster – context and framework

65% of thermal energy consumed in the city covered by DH (≈20 GWh/year). Main heat sources:

CHP plant for electricity supply of an oil and gas company (RAG)

Biomass heating plant Waste heat from a glass manufacturer

RAG is the Austrian oldest oil and gas company. 5km south of Kremsmünster RAG operates an oil and gas production facility = site for the Pitagoras plant (KRIFT)

To cover the electricity demand of their facilities, they operate a gas fired CHP plant with a maximum power of 2.400 kWe and 2650 kWth, covering around 75% of the DH supply of the city of Kremsmünster (15 GWh/year)

Kremsmünster

RAG (demo site)

PITAGORAS PLANTS - Kremsmünster 02

Kremsmünster – conceptual scheme

Large solar thermal plant (≈10.000m2) combined with seasonal thermal energy storage (≈60.000m3) for DH heat supply and internal process heat consumption.

PITAGORAS PLANTSDescription and results

03

Brescia pilot plant

RESULTS - Brescia 03

ORI MARTIN steel mill in Brescia


ORI MARTIN: melting steel scrap in Electric Arc Furnace (EAF) 25-30% of the used power is lost as waste heat (exhaust gas stream) Potential for energy recovery ⇒ efficiency increase

The new plant allows to recover the waste energy contained in the flue gas of the EAF:

• Summertime operation (April-October): electricity generation with ORC

• Heating season operation (October-April): heat delivery to DH net


PFD – Process Flow Diagram

Feed Water Tank ORC unit

EAF

WHB Steam Accumulator

DH system

MWth

MWth

MWe


WHRB + Steam Drum Steam Accumulator ORC turbogenerator

Heat substation for heat delivery to DH netSCADA


WHRU

Heat exchange between flue gases and water.

Very discontinuous process

• Average operating temperature: 500 ºC / 210 ºC (inlet/outlet).

• Nominal capacity: 16 MWth

• Expected thermal energy recovery: 52.000 MWhth/year.

STEAM ACCUMULATOR

150m3 storage to handle fluctuations

• Operation pressure: 10 - 24 bar(g)

• Operation temperature: 185 – 224 ºC.

• Storage capacity of 6 MWhth.

ORC

ORC supplied by Turboden.

Heat carrier: saturated steam.

Working fluid: silicone oil (MM).

• Design net efficiency 17,5 %.

• Nominal net output power: 1,8 MWe.

• Expected electricity generation: 4.200 MWh/year.

HEAT DELIVERY TO DH NET

Two equal steam-water heat exchangers

+ Flash Tank.

• Nominal capacity: 10 MWth.

• Expected thermal energy supply: 26.500 MWh/year

Main technical data


Performance of the plant

Operation mode: ORC (26.09.2016 – 16.10.2016, 115h of operation)

Average steam input to the ORC 6,8 MW

Average net power output ORC 1,3 MW

Average net efficiency ORC 19,3 %

Heat input to the ORC 790 MWh

Electricity output ORC 150 MWh

Operation mode: District Heating (17.10.2016 – 30.04.2017, 4.280h of operation)

Average heat input to district heating heat exchangers (steam) 5,2 MW

Heat input to district heating heat exchangers (steam) 22,4 GWh

Average heat output to district heating system 4,9 MW*

Heat output to the district heating system 21,0 GWh

The stated average power is calculated over the whole period of operation

* The difference between the average and nominal power exists due to the fact that the waste heat necessary foer the nominal DH-output was notavailable during this first period of operation. In the future this numbers wil be improved by means of process optimisation


Main technical challenge is related to the discontinuity of the available waste heat. The EAF works as a batch process due to the melting phase and the tapping phase

During the tapping phase the available waste heat and therefore the steam production is drastically reduced. Heat source highly fluctuating

Steady heat load is preferable for the DH and ORC for their safe operation key component: steam accumulator to smooth the steam supply

Main technical challenge


Discontinuous process

Steam accumulator

Recovered waste heat VS heat supplied


Environmental impacts assessment

• Embodied impacts of the Brescia pilot plant for

different scenarios depending on the type of

steel used for the construction of the plant

Electricity <10 gCO2/kWhe

Heat <1 gCO2/kWhth

• Impacts per produced energy:

• Avoided impacts due to produced energy:


Estimates of life cycle GHG emissions (gCO2eq/kWh) for categories of electricity generation technologies, including some technologies integrated with CCS. Source: SRREN (2011)

Pitagoras/Brescia < 10 gCO2/kWhe


Main economic figures

INVESTMENT

Waste heat recovery system 6,4 Mio. €

ORC module 1,5 Mio. €

DH net connection 0,4 Mio. €

Miscellaneous (civil works and engineering) 0,8 Mio. €

Total Installation Cost 9,1 Mio €

Plant adaptation costs 1,1 Mio. €

Innovation costs 1,8 Mio. €

Total Project Cost 12,0 Mio. €

Investment subsidies: EC – Pitagoras project * 2,5 Mio. €

COSTS

Operation and maintenance costs 0,18 Mio. €/a

REVENUES **

Revenues from heat sellings 0,5 Mio. €/a

Savings electricity costs 0,4 Mio. €/a

* The posible incomes from the selling of White Certificates (the Italian incentive mechanism for renewable projects) are not included

** Estimated values for future operation of the plant (optimized and in regular operation)

A first economic evaluation of the plant shows a payback period in the order of 12 years.The specific incentive mechanisms based on White Certificates that are in force currently in Italy reduce the payback time of the plant to 4-6 years.


Main barrier economic

- Investment payback times for the implementation of waste heat revalorization technologies arelonger than 3-4 years (usual time frame acceptable by industrial players).

- The most recent regulatory decisions taken in Italy reduce the incentives to ORC applications forwaste heat recovery and some DH support has been significantly reduced

- Incentives mechanism necessary to overcome this barrier. The new plant has been partially fundedby the European Commission (the remaining part: internal company investment)

- ESCO model could be an interesting alternative financial model (acceptance of projects with largertime for ROI than industrials)


Business model and key success factors

Awareness and willingness on both sides:1) Municipality (Brescia) and DH operator (a2a) high engagement to improve the energy mix and

reduce the carbon footprint of the city2) Industry (Ori Martin) highly committed to energy efficiency and sustainability

Business model: Public-Private Partnership (PPP): the DH system in Brescia is managed through a long-term concession (>30 years) between the Municipality and a2a (local DH utility)

Support from the municipality: since the DH grid commissioning in 1972, the Municipality of Brescia has strongly supported its deployment, following the best available practices towards an efficient and low carbon footprint network

Integrated approach, including long-term heat planning and following the best available practices and the use of local resources (waste-to-energy, industrial waste heat…)

Implemented solutions allow competitive prices and a profitable business:

- The payback of Brescia’s DHC investments was ≈15 years, already achieved

- Average price of DH is ≈70 €/MWh (excluding VAT), similar or lower than natural gas (most common alternative)


Benefits for all the stakeholders in the value chain:

DH UTILITY:

- Profitable business with a new energy source

- Increase of the fraction covered by RES/waste leading to a greener business

INDUSTRY:

- Increase of energy efficiency of the industrial process products with lower environmental impactand greener image of the company

- Effective business and financial model allowing the return of the investment through energy savingsand new incomes due to energy sales

CITY

- Economy based on green energy

- Step forward towards achieving the energy objectives (reduction of CO2 emissions, energy savingson fossil fuels consumption…)

Planned plant for the city of Kremsmünster

RESULTS - Kremsmünster 03

The high flow temperatures of the DH network (≈90ºC) reduces the possible solar energy gain to a high extent

Integration of a STES: store the solar heat from summer to winter so that it can be used for heating purposes inside the oil and gas production facility that needs very low heating temperatures

STES = an existing oil tank of 60,000 m3 of storage volume (that is no longer been used) will be reconverted into a STES

Layout for the Pitagoras plant

A solar field of 9.377 m2 (10.000 m2 of gross area) and 300 m3 of buffer storage

Hydraulic concept for the integration of the solar thermal plant in KRIFT. Source: Solid

Test field of 2500 m2 for different solar collector’s testing and selection of best one for the large solar plant at Kremsmünster. Source: Solid


Simulation results for the variant with a reconversion of one of the oil tanks into a STES. Solar system heat balance including a STES with 60.000 m3 (one of the existing tanks) and reduced set point temperatures for the collector circuit. Datasource: Solites, Graphics: Tecnalia

Simulations results on system performance

For the variant is shown in the figure:• No solar energy is fed into the DH net to avoid the high supply temperatures this heat sinks asks for• Solar energy is used in the heat sinks with the lowest temperatures 56% of solar fraction• Yearly solar net gain: 485 kWh/m2


Reconversion solution for the existing tank of 60.000 m3 to be used as STES. Source: Solites

Existing oil tank reconversion into STES

Detailed statical calculation of the existing tank necessary to prove its suitability to be used as STES

Most important issue: static stress, specially on the tank walls, caused by water stratification. It has to be proven that the entire storage construction can withstand that temperature stress on a long-term

Additional challenge in this case: floating lid of the existing tank. The only feasible alternative that has been concluded for this specific case is to fix the lid on topic o the storage volume

For more information:

http://pitagorasproject.eu

MANY THANKS FOR YOUR ATTENTION

For more information about PITAGORAS please contact:

[email protected]

[email protected]

mailto:[email protected]

mailto:[email protected]

xx/xx/2017 pitagoras project · pdf file-20% cut in greenhouse gas emissions 1 ... the new...

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