3 polyimex pgd small by Михаил Апакин

P OW E R G E N E RATION

POWER GENERATION DIVISION

CATALOG CONTENTS

1. GROUP  ��  4 2. ABOUT POLYIMPEX  ��  6 3. THE COGENERATION, TRIGENERATION PRINCIPLE  ��  8 4. COGENERATION SOLUTIONS  ��  10 5. TRIGENERATION SOLUTIONS  �� 11 6. APPLICATION AND MARKETS  �� 12 7. ABOUT INTERTECH  �� 14 • Company profile • CHP, CCHP units • Gensets • Twin-packs • Emergency power units

8. SCHEMATIC OF GAS TURBINE POWERED COGENERATION  ��  20 9. OPRA GAS TURBINE UNITS  ��  26 • Package specifications

10. THE ORGANIC RANKINE CYCLE  �� 30 11. THE ORC CYCLE  �� 32 12. TURBODEN ORC  �� 34 • Combined heat & power units

13. KOHLBACH  �� 38

GROUP

HIGH TECHNOLOGY FOR INNOVATIVE SOLUTIONS Polyimpex is a Swiss distributor of European heavy industrial equipment, such as industrial steam boilers, bioenergy boilers, burners and power generation engines and is one of the largest systems integrators in worldwide markets in heat and power engineering. OUR PARTNERS ARE WORLDWIDE LEADERS IN THE FIELD OF ENGINEERING AND CONSTRUCTION OF POWER FACILITIES. Weather your plant needs steam, hot or superheated water, power, you must rely on a competent and experienced partner. At Polyimpex our engineers will take care of your needs and study for you the best solution. Fast delivery, large amounts of products in stock, attractive prices, and quality control at every manufacturing step make our products highly competitive and suitable for world market for power systems.

4 MAIN DIRECTIONS COMBUSTION DIVISION Supplies burners for domestic use and for all industrial applications operated on traditional fuels, liquefied natural gas, biogas, diesel, oil and crude oil, as well as coal and wood dust

POWER GENERATION DIVISION OFFERS COMPLETE RANGE OF POWER GENERATION SOLUTIONS FOR ALL TYPES OF FUEL. In the world market of energy, we act as the Energy System Integrator and offer a broad choice of equipment and integrated turnkey solutions. Our equipment includes gas and dual-fuel turbines, dual-piston biogas installations, CHP & CCHP plants, thermal turbines based on ORC, cogeneration & trigeneration plants, energy systems, waste hear recovery boilers.

BOILERS DIVISION Supplies boilers for all applications, namely: our range of power for hot water boilers is from 150 kW to 140 MW, for steam boilers - up to 50,000 kg/h, for the biomass boilers - up to 6 MW, for domestic wall hung gas boilers - from 24 kW to 36 kW.

BIOENERGY DIVISION Offers effective solutions in biomass field, such as agriculture, wood processing and forest industry to generate steam, hot water and electricity.

ABOUT POWER GENERATION DIVISION Polyimpex was established to serve the growing global energy market. The need for high quality and affordable small and medium capacity power engines in the new millennium was so great that, as early as in 2012, the company started delivering its custom-designed, enhanced cogeneration units based on gas reciprocating engines. The companyâ&#x20AC;&#x2122;s mission today is to help customers operate in the energy market by implementing energy efficient technologies and reducing the time spent on equipment maintenance and the delivery of spare parts. The company's structure promotes efficient utilization of available resources, in order to achieve its primary goals Polyimpex follows global trends and offers comprehensive electrical heat and cooling generation services. We have a full range of solutions to meet your energy demands. Following the global electric and heat market trends, we offer a comprehensive range of services and power supply solutions for any situation. We will take on the burden of equipment maintenance during the warranty and beyond. Cogeneration and trigeneration technology can be used in any application where both electrical power and heat are required. The primary application is to supply power to residential and public buildings. Cogeneration and trigeneration technology is widely used in a variety of industries. The primary industries are: food and beverage, textiles, lumber, pulp-and-paper, oil rectification, cement and brick production, metallurgy, ceramics and glass manufacturing. Cogeneration and trigeneration units, also called engines, are very efficient when used at gas compressor stations away from power lines and heat supply systems, and at offshore gas, oil and other mineral recovery platforms. Individual low-capacity cogeneration and trigeneration engines (50 kW-2 MW) are well suited for small settlements or separate houses. In most cases there are two types of heat and power supply units: either a centralized electric and heat grid, or an individual cogeneration engine. Selecting the right option (centralized power supply or a local cogeneration and trigeneration engine) mostly depends on minimizing the capital and operational costs of installation.

SEPARATE PRODUCTION OF ELECTRICITY AND HEAT

Fuel 100%

Conventional Electric Power Plant

33% Electricity Efficiency

Fuel 100%

Conventional Boiler Hot Water

80% Heat Efficiency

Overall efficiency: (33+80)/200=0.565 or 56.5% 6

In some cases individual engines are required to supply additional electricity and heat. These are mostly used for backup. For example, at top class hotels, hospital facilities, airports, etc. The benefits of cogeneration engines in other applications are also obvious. Below are few examples displaying these benefits.

COMBINED PRODUCTION OF ELECTRICITY AND HEAT

42% Electricity Efficiency

Fuel 100% CHP

43% Heat Efficiency

Overall efficiency: (42+43)/100=0.85 or 85% 7

THE COGENERATION, TRIGENERATION PRINCIPLE Engine / generator

VEGETABLE OIL BIOETHANOL HEATING OIL NATURAL GAS

Fuel

COAL

Cogeneration

BIOMASS BIOGAS MUNICIPLE WASTE

Steam turbine

Gas turbine / generator

Power

plant

Heat

Generator

Cooling

COGENERATION SOLUTIONS Cogeneration systems are also known as combined heat

equipment ensures heat distribution. Generated power

and power (CHP) systems. They are designed to generate

is used by a facility or fed into the public power grid. The

both heat and power.

thermal energy can be used to generate heating water

CHP systems use waste heat accrued during an engine’s

and steam production as well as for various types of

operation to generate power. These installations have an

process heat. Gas engine cogeneration systems also are

overall efficiency of more than 90 percent. This efficient

used for CO2 fertilization in greenhouses and trigeneration

and economical method of energy conversion achieves

systems.

energy savings of roughly 40 percent by using a gas engine cogeneration system instead of separate power and

FEATURES & BENEFITS

heat generation equipment. Transportation and distribution • Cogeneration systems generate both heat and power losses also are reduced or eliminated as the decentralized

• CHP systems use waste heat from various sources to

energy supply is aligned where needed.

increase engine efficiency by up to 90% • Cogeneration achieves 40% energy savings vs. sepa-

HOW IT WORKS

rate power and heat generation equipment

CHP system includes an engine/generator unit and heat

• Reduces or eliminates transportation and distribution

exchangers that make use of waste heat. A wide range of heat sources (including engine coolant and oil, an air/fuel

losses • An addition of a boiler system or other heat storage me-

mixtures and exhaust gases) is configured to maximize benefits for each individual customer.

dium further increases operating time and efficiency • Generated power is used by an individual facility or fed

Cogeneration systems can be supplemented with a

into a public power grid

boiler system for bridging peak heat demand periods. An

• Thermal energy can be used to generate heating water

increase in system operating time and efficiency is made

and steam production, as well as for various types of

possible by connecting heat to a storage medium.

heating processes

Power engine electrical switch and control systems dis-

• Cogeneration systems also can be used for CO2 fertil-

tribute electricity and manage the engine, while hydraulic

ization in greenhouses and trigeneration systems

13% Head Loses Fuel 100%

30% Electricity

Cogeneration

55% Heat 2% Line Loses

TRIGENERATION SOLUTIONS Combined cooling, heating, and power (CCHP) systems,

imbalance, thereby forcing them to undergo desorp-

also called trigeneration systems, are a combination of

tion or absorption.

cogeneration engines and absorption chillers. They offer

3. Water (refrigerant) and lithium bromide salt (absorbent)

an optimal solution for generating air conditioning and/or

are generally used for generating chilled water in the

refrigeration.

temperature range of 6 to 12°C. Ammonia (refrigerant) and water (absorbent) are used for low temperature

Absorption chillers provide an economic and environmen-

chilling down to -60°C.

tal alternative to conventional refrigeration with compression chillers. Combining high efficiency, low-emission

FEATURES & BENEFITS

cogeneration equipment with absorption chillers enables

• Compared to conventional refrigeration technology,

maximum fuel efficiency, elimination of HCFC/CFC refriger-

absorption-based systems offer the most established,

ants, and reduced overall air emissions.

efficient, and economic solution for reducing emissions of air conditioning systems.

HOW IT WORKS

• Trigeneration systems operate with heat, utilizing rela-

Combining a cogeneration engine with an absorption

tively inexpensive «excess energy».

refrigeration system enables the use of excess season-

• The electricity produced can be fed into the public grid

al heat for cooling. Hot water from the cooling circuit of

or used to cover electricity requirements of the engine.

the cogeneration engine serves as drive energy for the

• During cold seasons, heat can be utilized to cover heat-

absorption chiller.

ing requirements.

1. Absorption chillers produce chilled water by heating

• The system contains no moving parts, enabling low

two substances (e.g., water and lithium bromide salt)

maintenance expenses.

that are in thermal equilibrium to separation, then

• The absorption system offers noiseless operation.

reuniting them through heat removal.

• There are low operating costs and life-cycle costs.

2. The heat input and removal is achieved in a vacuum at

• Using water as a refrigerant eliminates use of

varying pressure conditions (approximately 8 mbar and

ozone-damaging substances.

approximately 70 mbar), bringing the materials into an

13% Head Loses Fuel 100%

30% Electricity

Trigeneration

55% Heat 2% Line Loses

Cooling

APPLICATIONS AND MARKETS

POWER SOLUTIONS FOR THE OIL AND GAS AND MARINE MARKETS It is compact, efficient and reliable and therefore ideally suited for oil and gas and marine applications where reliability, space and environmental criteria are high priorities. Our standard generating set meets the most common standards required for operation in marine environments and is delivered with Class certification as required. COGENERATION (TRIGENERATION) APPLICATIONS FOR THE INDUSTRIAL AND COMMERCIAL MARKET Cogeneration is an economical, practical and environmentally friendly way to generate heat and power. It can be depended upon as a reliable, low emissions power source that efficiently generates cooling heat and electricity. Possible applications for use of the exhaust heat include: • Absorption cooling and air conditioning for district cooling • Hot water for district heating • Steam generation for process industry The low emissions and high exhaust temperature allows for direct use of the exhaust heat. Possible applications are: • Preheating of the inlet for a furnace, oven or conventional boiler • Drying applications, such as brick production • Direct drying of animal feed At full load, approximately 5MW of heat is available in the clean exhaust gases.

OIL AND GAS

MARINE

Offshore fields

Cruise ships

Onshore fields

Tankers

Pipelines

Special vessels

INDUSTRIAL

COMMERCIAL

Food processing

Hotels

Ceramics

Hospitals

Textiles

District heating

Specialty chemicals

and cooling

ABOUT INTERTECH

MAN MTU, ABC AND CUMMINS ENGINES ARE USED FOR GAS APPLICATIONS. We use common diesel engines, such as: MTU, Caterpillar, Cummins, Volvo, Deutz, MWM, Scania and so on. We use ABC-diesel, Rolls-Royce and MANB&W for high speed (1,500 rpm. for 50 Hz and 1,800 rpm for 60 Hz.) and midspeed generator sets (500 rpm, up to 1,200 rpm). We use Stamford Newage (Stamford), Marathon, Marelli, vanKaick, and others for generators. We use Woodward, Comap, Deepsea, Deif and others for control systems. We are an independent builder, and do our own engineering and manufacturing. We will never say "no", to questions concerning output, performance, or application. We have standard ranges in canopy built units, from 25 kVa, up 400 kVa, containerized sets from 400 kVa up to 3.000 kVa, as well as the whole range from 25 kVa up to 3.000 kVa in open sets, without closed roof. *) INTERTECH soundproof series generator set, uses a standard 20' or 40' container as a soundproof canopy *) This is the best selection especially for large capacity generator sets and power stations outside the home.

INTERTECH specializes in

*) Standard accessories for container

building custom units. New

soundproof canopies:

units are made to the customer's specifications. We try to

• Standard container

produce canopy generators

canopy with 20’ or

with the lowest possible noise

40’ ISO footprint

level, based on reliability,

• Built-in fuel tank for

durability, functionality, and

8-hour operation

usability requirements. We

• Built-in control panel

consider potentially restrictive

• Built-in battery start-

conditions, such as dimensions, weight and, of course,

up • Power output avail-

cost. We offer the client the

able in busbar and/

flexibility of choosing from

or connectors

major brands of motors and generators. Custom built diesel-generator sets are optimized to fit the needs of the customer.

• Air louver for intake and exhaust

• Muffler • Weatherproof installations • Soundproof installations • Container trailer installations • Compliant with the latest environmental regulations • High quality • Good price/quality ratio

COMPANY PROFILE

We are a 100% independent company that develops, builds and assembles: • Emergency power units

• Containerized Gensets

• CHP and CCHP units

• Twin Packs

Intertech Mechanical B.V. has a 2000 m2 modern workshop with 20 experts. This workshop contains high tech equipment and a 32 ton crane. All the units are built by Intertech Mechanical B.V. and undergo trial testing before delivery.

Intertech Mechanical B.V. has a testing area for diesel, gas, biogas- and bio oil engines, alternators, and complete units up to and including 6MWe and 3MWth. This includes a unique load cell test which has been in operation since 2001. Our fully equipped test cell has the capability to test: standard 400 Volt 50-600 Hz generator sets, gas engines, CHP and CCHP units and diesel or alternative fuel source engines.

• Resistive/reactive load bank with a

• Simultaneous testing of 2 units

maximum of 12.000 mWe, 690 Vdc

with 1,200 kWe or 6 CHP and

maximum, frequency independent.

CCHP-units with 200 kWe output

• Synchronizing and load share of generator set: 2–1,000 kWe. • Thermal heat input maximum of 4,000 kWth.

each. • Gas connection of 150 nm3 / hour @ 500 mBar. • Variable HV options (transformer)

• Grid/parallel synchronizing test:

6,10, 15, or 21 Volts.

maximum 300 kW.

We have our own design and engineering division. Here we design and engineer the units. The products/units electronics are developed and produced by Elmon.

OUR PRODUCTS • CHP and CCHP units • Gensets up to and including 2000 KW/600 Volt • Emergency power units 20, 30 and 40ft containers from 40 up to 2000 kVa • Specials

CHP & CCHP UNITS 18

COMBINED HEAT AND POWER & COMBINED COOLING, HEAT AND POWER

GAS

DIESEL

WHAT IS CHP AND CCHP Cogeneration CHP and trigeneration CCHP technology can be used in any application where both electrical power, heating and cooling are required. The primary application is to supply power to residential and public buildings. Cogeneration technology is widely used in various industries. The primary industries are: food and beverage, textiles, lumber, pulpand-paper, oil rectification, cement and brick production, metallurgy, ceramics and glass manufacturing. Cogeneration and trigeneration units, also called engines, are very efficient when used at gas compressor stations away from power lines and heat supply systems, and at offshore gas, oil and other mineral recovery platforms. Individual low-capacity cogeneration and trigeneration engines (50 kW-2 MW) are well suited for small settlements or separate houses. In most cases there are two types of heat and power supply units: either a centralized electric and heat grid, or an individual unit. Selecting the right option (Đ° centralized power supply or a local cogeneration unit) mostly depends on minimizing the capital and operational costs of installation. In some cases individual engines are required for supplying extra electric, heat and cooling supply. They are mostly used as a backup source. For example, at top class hotels, hospital facilities, airports, etc. The benefits of cogeneration engines in other applications are also obvious. Below are few examples displaying these benefits.

GENSETS 20

GENSETS

RENTAL

TWIN PACKS

GENERATOR SETS FOR RENTAL BUSINESSES Intertech Generator sets for rental business applications offer: • high reliability; • high class finishing; • operate in up to 45º C ambient temperatures; • simple operation; • very low noise levels; • communication with other controls and/or fabrications; • grid/synchronization, parallel and load-sharing possibilities/capabilities; • state of the art design with an optional feature for providing a self supporting loading/off loading system (-4- hydraulic legs). Electrical output from 50 kVA up to 400 kVA built-in a low noise canopy supplied by the customer. Built-in a 20 ft. custom made light weight shipping container, for outputs > of 300 kVA up to 1.700 kVA. Higher outputs can be obtained in a 30 ft. or 40 ft. container, or a custom-made container.

TWIN PACKS

Intertech BV company boasts a world-class track record and a 10-year history for manufacturing custom designed Twin Packs. An Intertech Twin Pack design is based on an ISO footprint, however it is customer-tailored and has a lightweight performance. Each Twin Pack container has two complete built-in generator sets. Its design enables the client to run the machine either separately in Island Mode or reconfigured for load sharing, effectively providing N+1 redundancy.

INTERTECH TWIN PACKS ARE DESIGNED TO PROVIDE: • high reliability;

• state of the art design with an optional feature

• high class finishing;

for providing a self supporting loading/offload-

• operate in up to 45º C ambient temperatures;

ing system (-4- hydraulic legs).

• simple operation;

• light weight design (appr. 11.5 ton for 20ft,

• very low noise levels;

2*500 kVA);

• communication with other control systems

• capacity to load two 20ft Twin Packs on a

and generator units;

standard truck and trailer.

• grid/synchronization, parallel and load-sharing possibilities/capabilities;

When the show must go on, Intertech Twin Packs will provide full automatic redundancy and are ideal for major broadcast and event companies.

EXAMPLES OF APPLICATIONS REQUIRING TWIN PACK GENERATORS: • Formula 1

• Parties

• Sporting Events

• Pop concerts

• Broadcasting

• Etc.

• Events

• Olympic Games

EMERGENCY POWER UNITS Emergency diesel power units: Intertech manufactures 20 kWe up to 500 kWe generator enclosures, 350 kWe up till 3,000 kWe containerized generators, and open generator installations of unlimited size and scope. All these units can be produced with diesel engines, gas engines and dual-fuel (diesel / gas) engines. Units have also been built for alternative fuels, such as: rapeseed oil, animal fat, palm oil and several other types of alternative fuels.

The possibilities are limitless: • 50 Hz and 60 Hz frequency and dual frequency

• Synchronizing • Net / parallel

• Low - and medium voltage

• Load sharing

• Medium- and high-speed engines

• Local or distance controlled

Intertech is an independent builder, not bound to, engine, generator and control system suppliers. This means that all brand and/or combinations are possible. It should be mentioned that Intertech specializes in tailor-made products.

SCHEMATIC OF GAS TUR COGENERATION WATER

HEAT RECOVERY UNIT

hot exhaust gases

GAS TURBINE

FUEL

BINE POWERED HOT WATER OR STREAM

HEATING OR COOLING

BUILDING OR FACILITY

electricity GENERATOR

POWER GRID

OPRA GAS TURBINES 2 MW UNITS

THE COMPANY OPRA Turbines is a leading global provider of turbine powered energy solutions. We develop, manufacture, market and service turbine generating sets in the 2 MW power range for use in single or multiple installations. OPRA has a team of professionals covering all aspects of a global gas turbine business. OPRA is dedicated to being a highly competitive company in its market segment by providing innovative products and maximum customer satisfaction. Continued improvement of products, processes and the organisation is an integral part of OPRA’s strategy and quality policy. OPRA offers a mobile version of its OP16-series gas turbine generators. These mobile packages can be rented from OPRA for any short or long term power requirement. OPRA’s OP16 Mobile Electric Power (MEP) packages are easy to install and relocate. The packages are designed with a standard 20ft containers footprint, every trailer will fit!

APPLICATIONS Typical mobile applications: • Construction Sites

• Emergency power for

• Special-Events

areas struck by natural

• Power during scheduled

disaster

maintenance events • Temporary additional power demand

• Electricity for military compounds in war zones • Electric Power for seasonal peak demands

SERVICES QUICK DELIVERY OPRA offers short delivery time on our mobile units. INSTALLATION & STARTUP OPRA can provide installation of the unit and take care of the first startup. OPERATION If required, OPRA can also provide qualified personnel to operate the units on site. 24HR ON-CALL SERVICE. At times of emergency, quick response and availability of service is critical. OPRA has a system in place that ensures availability of service around the clock, 365 days per year. Emergency calls can be made by phone during and outside of normal business hours. 27

PACKAGE SPECIFICATIONS GENERATOR

REAR VIEW

• Synchronous 4-pole, 3 phase • Open drip proof construction • Integral brushless exciter • 2250 kVA, 50/60 Hz, 400/480V • Acceleration vibration transducer • Integrated solid state AVR • H-class insulation • H-class temperature rise

1980 mm

OP 16 GAS TURBINE • Single shaft • Single stage centrifugal c ompressor • Single stage radial turbine • 4 can combustion system

FRONT VIEW

• Dual fuel and DLE combustion system • High energy spark ignition s ystem

1850 mm

GEAR REDUCTION • Integral epicyclical gear • 1500 or 1800 rpm • Acceleration vibration transducer • Ancillary drive shafts • Shear pin drive shaft protection

SIDE VIEW

5400 mm 28

OUTPUT SHAFT

AIR INLET

COMPRESSOR

COMBUSTION CHAMBERS

EXHAUST DIFFUSER

REDUCTION GEAR

BEARING HOUSING TURBINE

OP16 INNOVATIONS SIMPLE AND ROBUST

load when specified as a dual fuel unit. The

The all-radial turbine rotor is sophisticated

turbine runs well on low calorific value fuels

simplicity at its best, resulting in a robust

such as biogas.

design for high reliability and dependability. Its unique configuration, efficient flow path

CANTILEVERED ROTOR SYSTEM

and advanced metallurgy results in a com-

The cantilevered rotor system places both

pact gas turbine suitable for the harshest

bearings in the cold part of the engine. This

conditions.

results in extended bearing life and virtually zero oil consumption.

EFFICIENT The OP16 industrial turbine offers the high-

LOW EMISSIONS

est fuel efficiency in its power range. When

Advanced combustion technology allows the

used in a Combined Heat and Power system

turbine to achieve guaranteed NOx exhaust

overall thermal efficiency of 90% can be

levels of 25 ppm or less. Optional equipment

achieved.

may provide even lower levels when required.

COMPACT The turbineâ&#x20AC;&#x2122;s compact size is a direct result

MODERATE PRESSURE RATIO

of the all-radial rotor design and a much

The turbineâ&#x20AC;&#x2122;s moderate pressure ratio of 6.7:1

shorter flow path through the engine. The

reduces the requirement for gas fuel boost

compact rotor allows a smaller generator set

compressors compared to other gas turbines.

footprint and reduced installation requirements.

ECONOMICAL With a high fuel efficiency, compact installa-

FUEL FLEXIBILITY

tion, and excellent reliability, the generator

The turbine operates equally well on liquid

set offers both low installation and operating

and gaseous fuels and can switch under full

costs. 29

THE ORGANIC RANKINE CYCLE The Organic Rankine Cycle technology (ORC) is very similar to the one used in steam cycles (Rankine Cycle): a working fluid is heated up then vaporized thanks to a heat source. The produced steam is then expanded into a turbine to produce mechanical energy then electricity using an alternator. The fluid is then condensed to close the thermodynamic cycle (schematized on the following figure). This cycle bears its name from the Scottish physicist William Rankine (19th century) who enabled the production of electrical power. The difference between a classical cycle and an organic cycle is the working fluid: in ORC modules, water is replaced by an organic fluid. Rankine cycle has proven reliable in every thermal steam power plant using fossil, biomass or nuclear fuels. However, this cycle using steam turbine efficiency does not recover low temperature heat sources with efficiency or can’t be used in small scale power plants that are competitive. By replacing water with another fluid – chosen according to the heat source temperature – it is possible to build efficient and compact modules, adapted to several applications (small scale biomass cogeneration, thermodynamic solarpower, low temperature heat recovery, etc.). Among all the available fluids, the ones from carbon chemistry are preferred, thus we call them ORGANIC RANKINE CYCLES (organic chemistry = carbon chemistry) also called ORC. When we look at ORC technology, we ask ourselves about the interest of replacing water by an organic fluid. Water is “free”, with no risk for men and the environment, and has been used since 18th century for thermodynamic cycle applications. Why change ?

THERMAL OIL

ORC MODULE

COOLING SYSTEM

Turbine

Generator Evaporator

Heat sources: biomass, heat recovery, solar

Condenser

Regenerator

Cogeneration / air cooler

THE THERMODYNAMIC PRINCIPLE: THE ORC CYCLE

l ma

r he

TEMPERATURE

oil

Turbine Electric power

4 5

4 3

Thermal oil

Regenerator 9

Evaporator 6 r Wate

Water

9 2

Generator

ENTROPY

2 Pump

Condenser

WATER

ORGANIC FLUID

• Small, fast moving mole-

• Very large flow rate

cules

High molecular mass fluid

• Metal parts and blade erosion

• Larger diameter turbine • No wear of blades and metal parts

• Multistage turbine and high mechanical stress

WATER DOES NOT ONLY HAVE ADVANTAGES. WE CAN LIST IN PARTICULAR: • The necessity to have a hot source over 400°C to get an efficient cycle economically profitable. • An operation with pressure over 40 bars that involves permanent surveillance of the installation. • The necessity to implement costly auxiliaries such as demineralization systems. These fixed costs restrict installations over 2MWe. • The difficulty to find reliable manufacturers for small scale installations . • The important wear of the turbine due to liquid water at the end of the expansion phase. This last point in particular is important when comparing ORC and steam cycles. Water is a “wetting agent” . When steam is expanded in the turbine, water drops can appear and damage the blades. On the contrary, organic fluids used in ORC are called “dry” fluids, i.e. that fluid expanded in the turbine is always in a gaseous phase. This enables to increase the life of the turbines and to reduce operation and maintenance costs. ORC bring true solutions to these issues. The technology enables to produce power from a low temperature heat source (down to 70°C). According to the hot source temperature, it is also possible to cogenerate (to produce Combined Heat and Power).

TURBODEN ORC (ORGANIC RANKINE CYCLE) TURBOGENERATORS

THE COMPANY Turboden is a leading European company in development and production of ORC (Organic Rankine Cycle) turbogenerators. This state of the art equipment generates heat and power from renewable sources and heat recovery in industrial processes. Turboden has always had a single mission: design ORC turbogenerators for the production of heat and electrical power from renewable sources, while constantly striving to implement ORC technical solutions. In 2009, Turboden became part of Pratt & Whitney (UTC Corp.), a worldwide leader in development, production and service for aero engines, aerospace drive systems and heavy duty gas turbines. Today Turboden is part of Pratt & Whitney Power Systems (PWPS), to develop ORC solutions from renewable sources and waste heat worldwide. Turboden designs and develops turbogenerators based on the Organic Rankine Cycle (ORC), a technology for the combined generation of heat and electrical power from various renewable sources, particularly suitable for distributed generation.

STANDARD UNITS FROM 600 KW TO 6 MW CUSTOMIZED SOLUTIONS UP TO 15 MW

LAYOUT – SOME EXAMPLES

TURBODEN 7 layout

TURBODEN 10 layout

TURBODEN 18 layout

HEAT RECOVERY Turboden ORCs can produce electricity by recovering heat from industrial processes, reciprocating engines and gas turbines. The power of Turboden Turbogenerators in this application generally ranges between 600 kW and 10 MW electric.

ADVANTAGES OF TURBODEN ORC TURBOGENERATORS TECHNICAL ADVANTAGES • High cycle efficiency • Very high turbine efficiency (up to 90%) • Low mechanical stress of the turbine thanks to the low peripheral speed

OPERATIONAL ADVANTAGES / RESULTS • Low RPM of the turbine

• Simple start-stop proce-

allowing the direct drive of the electric generator

dures • Automatic and continuous

without reduction gear • No erosion of blades,

operation • No operator attendance

thanks to the absence

needed

of moisture in the vapor

• Quiet operation

nozzles

• High Availability (> 98%) 35

• Partial load operation down to 10% of nominal power • High efficiency even at partial load • Low O&M requirements: about 3-5 hours / week • Long life

COMBINED HEAT & POWER UNITS OUR PRODUCTS FOR WOOD BIOMASS APPLICATIONS To date most of Turboden’s projects are in the field of cogeneration from wood biomass. Turboden turbogenerators electric power output generally ranges between 200 kW and 15 MW. The Turboden split system allows maximising electric power production for a given biomass consumption. COMBINED HEAT AND POWER STANDARD MODELS Turboden offers different standard models for CHP cogeneration: • TURBODEN 6 CHP: around 600 kW net active electric power • TURBODEN 7 CHP: around 700 kW net active electric power • TURBODEN 10 CHP: around 1000 kW net active electric power • TURBODEN 14 CHP: around 1300 kW net active electric power • TURBODEN 18 CHP: around 1800 kW net active electric power • TURBODEN 22 CHP: around 2200 kW net active electric power • TURBODEN 30 CHP: around 3000 kW net active electric power

HEAT RECOVERY UNITS OUR PRODUCTS FOR WASTE HEAT RECOVERY APPLICATIONS Turboden ORC technology is particularly suitable for producing electric energy by recovering heat from industrial processes and combined cycle systems. Turboden turbogenerators electric power output generally ranges between 200 kW and 15 MW electric. HEAT RECOVERY STANDARD MODELS Turboden offers different standard models for Heat Recovery, with the following typical performances in terms of net active electric production: • TURBODEN 6 to 7 HR: 480-760 kW • TURBODEN 10 to 14 HR: 850-1550 kW • TURBODEN 18 to 24 HR: around 1650-2400 kW • TURBODEN 27 to 40 HR: around 2500-4000 kW • TURBODEN 50 to 100 HR: around 4500-9800 kW

HIGH ELECTRICAL EFFICIENCY UNITS OUR UNITS FOR ELECTRICITY GENERATION AND COGENERATION FROM BIOMASS Turboden developed models of turbogenerators HRS capable of ensuring high performance in terms of electrical efficiency in contexts with a strong presence of agricultural and forest biomass, but with discontinuous ability to allocate the heat.

HRS models can operate both in dissipative regime, maximizing the electrical output, and in cogeneration, with the opportunity to provide heat to any seasonal thermal load and making the most of the biomass. HRS STANDARD MODELS Turboden offers several HRS units: • TURBODEN 12 HRS – split: up to 1140 kW net active electric power production • TURBODEN 24 HRS – split: up to 2250 kW net active electric power production • TURBODEN 32 HRS – split: up to 3000 kW net active electric power production • TURBODEN 55 HRS – split: up to 5000 kW net active electric power production • TURBODEN 65 HRS – split: up to 6000 kW net active electric power production • TURBODEN 110 HRS – split: up to 10000 kW net active electric power production

TAILORED SOLUTIONS PRODUCTS TAILORED TO YOUR NEEDS Apart from standard sizes and applications, Turboden designs and manufactures customized units for special applications or sizes (such as heat recovery and geothermal up to 15 MW). SOME EXAMPLES OF SPECIAL UNITS Geothermal plants: 3 geothermal ORC plants were designed, produced, installed and started-up in Bavaria in 2013. These units, 5+ MW each, are air-cooled and prepared to supply heat to the existing district heating network. In 2012 Turboden started up the first supercritical ORC plant in Europe, a 500 kW prototype with hybrid direct cooling, and tested its flexibility with highly variable heat input. Low temperature heat recovery units: Turboden supplied an ORC unit in Belgium to recover heat from pressurized water boiler in waste incinerator. Thanks to Turboden ORC it has been possible to maximize the potential of the incinerator. Heat recovery plants an innovative project was installed in Russia to recover heat from the associated gas coming from Oil Extraction through controlled combustion (instead of flaring); a heat recovery ORC unit was coupled with five MTU engines, 2 MWe each. Other examples are the heat recovery units employed in cement production processes: a 4 MW ORC in Romania, that recovers waste heat from the kiln and clinker cooler exhaust gas; a 2 MW unit in Morocco, a 5 MW module in Slovakia. One of the latest Turboden innovative projects is a new 3 MW ORC unit, that uses part of the saturated steam produced by recovering heat of the exhaust gasses from the EAF (Electric Arc Furnace), in Germany. 37

KOHLBACH WE MANAGE THE ENTIRE PROCESS FOR YOU: BIOMASS PLANTS WITH IQ: LISTEN, OBSERVE, UNDERSTAND The many years of practical experience of plant operators in the daily production of energy from biomass as well as market changes are a constant contribution to Kohlbach’s continued development. We also carry out regular test runs for our customers and then immediately incorporate the results into the system concept. Our plant is always “state of the art”, which is why we put our name on it. PROJECT MANAGEMENT Every single system is adapted to the individual requirements of the customer - thus the customer receives their own custom solution. To do so our customers receive complementary support by an experienced project manager right from the very start. MANUFACTURING All significant components from the fuel logistics to the de-ashing, as well as all combustion and boiler systems are produced and assembled by our employees in our own production facilities with the highest level of technical precision. Our highly qualified specialists and professionals manufacture your system components with dedication, pride and a sense of responsibility, for your head start with proven our quality.

The Kohlbach Group is THE innovative and efficient enterprise in the biomass boiler plant manufacturing industry with its own facilities in Austria, Germany, France and Croatia. A family owned business with 250 employees, more than 60 years of experience and already more than 1,500 installed systems. • reliable plant technology and outstanding quality • continuous development and innovative products through R & D • one of the largest employers and provider of vocational training in the region • multiple awards for economic, environmental and social responsibility

RELIABLE HEAT SUPPLY Our biomass boiler plants assure a reliable and efficient supply of heat from 400 to 18,000 kW per module: • Warm/hot water boilers: Warm water up to 110 °C and hot water up to 200 °C, 2 or 3 pass • Steam boilers: From 0.5 to 40 bar, hot steam temperatures up to 450 °C • Thermal oil boilers: Process heat at high temperature levels (supply temperatures > 150 °C to 315 °C) Our boiler systems are ideal for the heat supply of district heating of communities, environmentally-sensitive tourist locations, factories, productions halls, as well as the supply of drying kilns or steam chambers, dairy production, breweries, hospitals, nurseries, and much more.

RELIABLE SUPPLY OF HEAT AND ELECTRICITY The simultaneous generation of power and heat from biomass is the supreme discipline of biomass utilisation. Therefore, our boilers are designed in special capacity ranges attuned to common turbine module sizes: • High-pressure steam boilers for steam turbines and engines: Fire tube boilers up to 40 bar or water tube boilers for higher pressure levels • Thermal oil boiler plants for ORC technology (Organic Rankine Cycle): For small combined heat and power plants ranging from 200-3,000 kW electric, low pressure boiler circuit operation, very high overall system

APPLICATIONS Around the energy from wood and biomass, we offer our customers an extensive range of services and products. Enjoy the advantages of a complete provider, from the fuel logistics, through furnace and boiler systems, flue gas cleaning, flue gas condensers up to chimneys: immerse yourself in the world of our solutions. • efficient supply of heat from 400 to 18,000

• highest quality and economical solutions for

kW per module or of electricity and heat from about 1,500 kW

every application • exemplary high levels of efficiency

• individually designed boilers for our customer • robust and reliable needs: different rated outputs, temperature and pressure levels 39

SOLUTIONS

BOILERS COMBUSTION

POWER GENERATION GAS & OIL

BIOENERGY

Polyimpex Trading AG Industriestrasse 7, P.O. Box, CH-6300 Zug, Switzerland Tel.:+41 (0) 41 725 05 95 Fax: +41 (0) 41 725 05 96 info@polyimpex.ch