ORGANIC RANKINE CYCLE -...

ORGANICRANKINECYCLEPower plants for

� biomass

� geothermal energy

� waste heat recovery

Germania Technologieholding GmbH

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Germania Technologieholding GmbH (GERMANIA) and its subsidiaries such as GMK (Gesellschaft für Mo-toren und Kraftanlagen mbH), GAB (Germania Apparatebau GmbH), and GBV (Germania Besitz- und Verwaltungsgesellschaft mbH) are

focused on developing and engineer-ing energy efficiency technologies.

„Efficiency technologies“ are basi-cally to be understood as ORC-power devices used for the conversion of geothermal heat, industrial waste heat and heat from biomass c o m b u s t i o n into electricity. Fu r t he rmore the company is a producer of high pres-sure apparatuses for the chemical industry business, the power plant industry as well as applications for highest pressure devices up to 9.000 bar for international research institu-tions. During the past, GERMANIA was successfully realizing and im-plementing several large projects for the CERN (Conseil Européen pour la Recherche Nucléaire) in Geneva and other honourable scientific institutes. The company holds important certifi-cates for the manufacturing of pres-sure devices (HP-0) and moreover it is certified for the production of nu-

clear high pressure aggregates ac-cording to the German and French nuclear technology code. In addition, Germania had been certified with a quality management system accord-ing to the ISO 9000 (2000). The GERMANIA companies are located at the traditional-rich production site of the former GERMANIA manufac-turing area where a high number of crude oil apparatuses used to be manufactured for Russian refineries. Germania’s production site is going to celebrate its two hundredth anni-versary in 2011.

At GMK, that is located close to the in-ternational harbour of Rostock at the Baltic Sea, you will find the research and development department espe-cially operating in ORC-substance design, power plant layout and prod-

uct development of GERMANIA pow-er plants. Based on the given produc-tion capacities at the engineering site in Rostock an automated production of plate heat exchangers has been in-stalled at GMK, too. Germania’s larg-er heat exchangers of ORC-modules are being constructed at the manu-facturing site in Chemnitz. Besides prior mentioned core activities classi-cal apparatus production projects are being realized as well. Such as spear parts for clients from C.I.S. are being produced mainly for customers from the petrochemical industry business.

Short OverviewIn case of the ORC-cycle process, heat is removed from a high temper-ature reservoir, which is partly add-ed to a second reservoir with lower temperatures later on. The removed heat performs mechanical work as steam in turbines. After this proce-dure the steam condenses and is re-introduced into the cycle in a liquid state. The most important variables for this process are the pressure and temperature in the different phases of the cycle. Instead of water, an organ-ic medium with a low boiling point circulates in ORC-power plants, which is capable of performing work at temperatures as low as 90°C and pressures less than 20 bar. This way the ORC-process offers the capability to transform heat on low temperature levels of all kind into electricity.

The ProcessEnergy is removed through the evap-orator � from the primary medium, for example hot water, thermal oil or exhaust and is applied to an organic working medium, which is in the sec-ondary cycle of the evaporator � . This medium is a chlorine free, non toxic, substance with a zero percent ozone depletion potential with a low boiling point, like silicone oil.

Because of the physical properties of the working mediums, they expand when charged by the high energy primary medium. The working me-dium, which is in a vaporous state, flows over the fresh steam pipe � to the ORC-turbine �, where it per-forms expansion work. This work is transformed into electricity by the generator � . After leaving the tur-

bine the steam flows into the recuper-ator � where its remaining energy is released into the liquid working medium. Following to this procedure the exhaust steam, is cooled down just over its condensa-tion temperature and flows into the con-denser � . There it is liquefied and drawn from the feed pump � over the Hotwell. The pump adjusts to the needed working pressure and forces the working medium over the recuperator � to the pre-heater and the evapora-tor � to close the cy-cle.

By summarizing all activi-ties that are necessary for the production of ORC-power plants in a company group, GERMANIA is capable to plan and realize complete ORC-power plant projects with a power range from 50 - 5.000 kW.

Largest shareholder of the

GERMANIA group is the

PAPALIN foundation, located

in Vaduz, Liechtenstein. Due

to their commitment the group

had been fully restructured

and supplied with fresh capi-

tal. Therefore, the company is

able to realize large projects

in the area of environmental

and efficiency technologies

with well qualified engineers

now.

ORC – a thermodynamic cycle which is the tech-nological basic principle of our products

The ORC-process (Organic-

Rankine-Cycle) is a thermody-

namic cycle named after Wil-

liam Rankine, a British expert

on thermodynamics, who had

already described the process

of ORC-engines by the mid

19th century. ORC-engines

transform thermal energy into

electricity at temperatures and

pressures far lower than those

of conventional water-steam

power plants.

The Company The ORC-Process

GEOCAL® ORC-power plants for geothermal heat sources

INDUCAL® ORC-power plants for waste heat recovery

ECOCAL® ORC-power plants for biomass

GEOCAL®-power plants offer the technological solution based on the ORC-process to exploit huge geo-thermal potentials. Thermal water �, with temperatures ranging from 90°C to 250°C, rises to the ground surface, either directly from hot water aquifers or due to the Hot-Dry-Rock principle, and flows through an evap-orator � that consists of special salt resistant metal alloys because of the high content of salt and solute gases in the thermal water �. The thermal water that is cooled down to approxi-mately 60°C to 70°C, can be reintro-duced into the drill hole � or serve to supply a district heating system. In the evaporator � the heat energy of the thermal water is transferred to an

organic working medium which is in the secondary cycle of the evapo-rator �. This medium is a special working fluid patented by the GMK. Because of its physical properties it expands when charged by the high energy thermal water and flows over the fresh steam pipe � to the ORC-turbine �, where it performs expan-sion work by decompressing. The turbine is an ORC-turbine of the AFA

series produced by former AG KK&K (today SIEMENS Turbomachinery Equipment GmbH). The turbine is con-nected with a generator � for the production of electric-ity. The energy produced can be fed into the open energy network and remunerated with privileged conditions in accordance with the EEG (renewable energy act Ger-many). After the steam passes through the turbine it flows into the recuperator �, where it relin-quishes the remaining energy to the liquid working medium. Afterwards, the steam flows into the condenser � , which is cooled by a wet or an dry

by air cooling tower . In the condenser � the working medium is liq-uefied and in-troduced over the Hotwell to the feed pump �. It transports the medium over the recu-perator to the preheater / evaporator �

to close and continue the cycle.

GEOCAL® working mediums are environmental-friendly, chlorine free, cost effective and free of all toxic components. GEOCAL®-working mediums are unique because of their chemical properties and efficiency!

In competition with other thermody-namic cycles GEOCAL®-modules achieve the highest theoretical elec-trical efficiency in temperature fields typical for the geological formations

in

middle Europe because of their pat-ented and sophisticated construction properties as well as their data of working media.

PhilosophyThe known geothermal po-

tential in Germany is so large

that the yearly electrical base

load of 300.000 Giga watt

hours could be produced

over a period of time of 600

years*. Exploit this ecologi-

cally energy potential is the

motivation for us to develop

advanced technologies based

on efficiency and environ-

mental friendliness.

*bibliography: Paschen, Herbert et al, Möglichkeiten geothermischer Stromerzeugung in Deutschland, TAB 84, Feb. 2003

In competition with oth-

er thermodynamic cycles

GEOCAL®-modules achieve

the highest theoretical electri-

cal efficiency in temperature

fields typical for the geologi-

cal formations in middle Eu-

rope because of their patented

and sophisticated construc-

tion properties as well as their

data of working media.

GEOCAL®

Electrical Power Output:0,5 – 6,0 MW

Thermal Power Output:3,0 – 50,0 MW

Operating Time:8.000 h per year

Staff0,1 – 4,0 employees

ECOCAL®-modules are power plants based on the ORC-process and mainly used for the production of electricity from solid plant biomass. They offer the capability of optimiz-ing the efficiency of small and aver-age renewable energy power plants. Wood for the production of energy and waste timber from the indus-try, which comes from the region, is stored in the fuel-silo. From there it is transported into the firebox over the scraper conveyer. Inside the firebox the biomass is burned producing low emissions. The highly energized gas flows through the thermal oil boiler on the way to the chimney. There it releases its energy to thermal oil, which has a high boiling point, heat-ing it up to about 300°C.

The thermal oil is carried off over a pipe system to the evaporator. There, the thermal energy from the oil is transferred to an organic medium, which is in the secondary cycle of the evaporator. Because the boiler works with a thermal oil, pressure is not needed for the heat transfer (primary

cycle) to the real working medium (secondary cycle).The firing observation, therefore, is not affected by the regulations of pres-sure steam boilers. The organic steam flows over the fresh steam pipe to the turbine, which is produced by the former AG KK&K (today SIEMENS Tur-bomachinery Equip-ment GmbH) series. There, the steam per-forms expansion work, which is converted to mechanical and electrical energy. After leaving the turbine the steam get into the recuperator / condenser to transfer the conden-sation energy to the water heating system. The condensed and liquefied working medium is retracted by the condensate feed pump and brought up to working pressure, closing the cycle.

GERMANIA produces ECOCAL®- modules with electrical power ca-pacities ranging from 500 kW to 2,000 kW. Lower power modules are specific applications that have to be planned separately. The working me-diums used by GERMANIA are high-ly efficient, environmentally friendly, cost effective and free of all toxic

substances. The ORC-power plants that have been built are operating on untreated wood only. The pur-chase of wood causes an increase of the regional high regard. Also using ECOCAL®-power plants can lower the cost of district heating in commu-nities by 30 percent.

PhilosophyThe present available poten-

tial of solid biomass in the

German-speaking Europe is

so great, that about 8 percent

of the electrical base load in

Germany could be replaced

with renewable biomass.

Exploiting this environmen-

tal friendly energy potential

motivates us to develop ad-

vanced Technologies.

� fuel-silo

� scraper conveyor

� hydraulic drawer

� firebox with fire room

� thermal-oil-boiler

� flue gas tube

� induced draught fan

chimney

generator

� transformer

� open energy network

� fore run

� evaporator

� thermal-oil-cycle-pump

� recoil

� secondary cycle- fore run

(working fluid)

� ORC-turbine

� turbine exhaust steam

� condenser

� water district heat-fore run

� water district heat-recoil

� consumer

� hydraulic stair grill

� slag lock

� exhaust cyclone

� slag container

� condensate feed pump

ECOCAL®



Fuel requirement:6.000 – 20.000 t per year



Legend

Generally waste heat from industrial facilities has a low temperature (up to 400 °C), but appears in enormous volumes. This makes it difficult to de-velop such large energy potentials economically with the classic water-steam process because of high invest-ment costs and low thermodynamic efficiency factors. The INDUCAL®-process offers the possibility to ef-ficiently transform these energy po-tentials into electricity through the ORC-process. For the optimal use of the heat source a working medium is selected, depending on the tempera-ture and the quantity of the exhaust, that will show a preferablyhigh evaporation pressure at the ex-pected working temperature of the cycle. The pressure limit in a plant has to be less than 20 bars to conform with the Steam Boiler Code (Damp-fkV). Because of this it is possible to operate INDUCAL®-ORC power plants fully automated without super-vision according to the Steam Boiler Code. Incoming industrial waste heat can be collected using a thermal oil cycle (primary cycle) and transferred with the pre-heater vaporizer unit to the working fluid (secondary cycle) which is in the ORC-module. After this process the vaporized work-ing medium runs through the ORC-turbine. In this ORC-turbo generator the thermal energy of the working medium is transformed into electric-ity. Afterwards the spent, gaseous working fluid is transferred from the ORC-turbo generator directly into the recuperator- condenser unit to be liq-uefied as also to give its remaining energy to the liquid working medium in the counter flow.

Using the condensation heat is not possible most of the time, because the condensation temperature lies slightly higher than the ambient air temperature.

Most of the time INDUCAL®-power plants are power-operated. There-fore the produced electricity can be used to supply the industrial compa-nies themselves or can be fed into the power grid. The expansion machines used are either turbines or screw en-gines depending on the power of the heat source. From a thermal power of about 2 MW the ORC-turbine series AFA10 from the former company AG KK&K (today SIEMENS Tur-bomachinery E q u i p m e n t GmbH) is used. At smaller thermal power outputs, such

as waste heat from biogas engines, screw motors are used (IC 60 mod-ule) The electrical efficiencies of the INDUCAL®-modules range from 9 to 21 percent, depending on the quality of the heat source.

PhilosophyBy using the INDUCAL®

power plants 5-8 percent

of the electricity used in the

whole European industry can

be generated from waste heat

resources. (Resource: MBB

study 8/91)

� gen-set

� fuel tanks

� exhaust heat exchanger

� thermal oil cycle/

primary cycle

� thermal oil pump

� pre-heater evaporator unit

� fresh steam pipe/

secondary cycle

ORC-turbine

generator

� condenser

� condensate-feed pump

� cooling cycle

INDUCAL® Legend





LIPOCAL® is a continuously working process, in which fat and oil with a high content of free fatty acids can be transformed into a raw material similar to fat. Since 2002 this proc-ess worldwide patented by the GMK, has made it possible to produce this raw material with an efficiency of 95 percent. Raw fat or oil is delivered, stored and if needed separated from solid matter. From the storage unit, the acidic fat goes into the esterifi-cation column where the reaction in company of catalysts with a polyva-lent alcohol takes place. Due to the reaction with the polyvalent alcohol, the concentration of free fat acids is lowered without changing the phys-ical-chemical properties of the neu-tral fat. After water-soluble pollutants are cleared in the following cleaning stage, the fat is available as a mate-rial similar to fresh fat.

LIPOCAL® neutralised oils and fats are suitable for direct use as fuel in stationary heavy oil en-gines, also for the environmentally

friendly production of numerous chemical substances. The end prod-uct may be used for fabrication of building materials, lubricants, fatty

alcohol and detergents up to envi-ronmentally friendly preservation agents for wood or foams for fire ex-tinguisher.

PhilosophyAs an energy source pro-

vided from nature, fats and

oils are suitable as a valu-

able raw material. On the

one hand these materials can

be used for the chemical in-

dustry to produce environ-

mentally friendly products, on

the other hand they can be

directly applied as fuel in sta-

tionary heavy oil engines to

produce electricity and heat.

Most of the biological unused

fat and oil can not be used

without being processed. The

LIPOCAL®-process offers a

solution to convert those un-

used resources into valuable

raw materials and fuels.

� delivery with tanker

� 40 m³ storage container

with stirring unit

� mechanical separation of

delivered old fat

� heating and transfer to

the reaction gang

� reaction column

� solid bed catalysts

� vacuum pump

condensation unit

metering unit for

reaction agents

� pump for taking the

reaction product

� small storage tank

� inlet for rest lye

� fuel pipeline

� LIPOCAL® -motor heat and

power plant

�generator

� open energy network

� district heating system

LIPOCAL®

Combined motor heat and power plant



Fuel requirement:2.000 – 10.000 t per year



Legend

»Germania Apparatebau GmbH« has a long history in the sector of German apparatus engineering. The company’s roots in this business can be traced back to the beginning of the 19th century. In 1811 J. S. Schwalbe founded the »Maschinen-fabrik Germania J.S. Schwalbe & Sohn« in Chemnitz, Germany. GER-MANIA belonged to Germany’s most significant boiler and chemistry ap-paratus producers as early as 1856. The company grew constantly, until the main factory’s production area had to be increased over 10,000 m² in the year 1900 to concentrate on the construction of steam boilers for trains, chemistry plants, and most of

all heat exchangers for the growing industry. After the plant was close to its complete destruction in the Sec-ond World War it has been rebuilt after it was repossessed as public property and renamed »VEB Appa-rate- und Anlagenbau Germania«. After its repossession, the company produced plants and apparatuses for the chemical industry. In addition to the classic reaction gangs and reac-

tors the company started producing devices for nuclear technology as well as high pressure components up to 9,000 bars. Even at this time the company exported its products worldwide to all large companies of the chemical and petrochemical in-dustry. »GERMANIA« produced im-portant components for the Russian / Soviet petroleum industry and con-tinues to supply these industries with spare parts today.

History after 1990Today the succeeding company – »Germania Apparatebau GmbH« after its intricate history, returns to become one of Europe’s most innova-tive apparatus producers. In the past years important projects were suc-cessfully executed for renowned cus-tomers in the area of particle phys-ics, energy technology, and classic petrochemistry. In the year 2000 the cooperation with todays GERMANIA group began, since the Germania Apparatebau GmbH is one of the few companies capable of producing main components for ORC-power plants. Today Germania Apparate-bau GmbH is integrated into the GERMANIA group as a 100 percent subsidiary.

The basis of our company philosophyGERMANIA has been successful for 200 years in the (energy) apparatus production. In addition to the tradi-tional expertise and knowledge, our

engineers, scientists and workers are also skilled in areas of modern tech-nology. Our information database has been built up trough generations of employees and can be accessed in the large archive today. The use of traditional knowledge, the devel-opment of 3D constructions of all products and instruments, new meth-ods for numeric calculations as well as the use of CFD-flow simulations establish a basis for a diverse per-spective of apparatus engineering. Utilizing these strengths in our com-pany high pressure machinery, able to sustain a pressure of 8,000 bar, or large heat exchangers weighting 60 tons made of high or low alloyed steels, are being produced by GER-MANIA today.

Apparatus Engineering

Research and development form the basis for the engineering and manu-facturing of ORC-power plants, its main components and the working media. The core competencies are being reflected by the research and development department at GMK (Gesellschaft für Motoren und Kraf-tanlagen mbH) within the holding.

GMK was founded in 1994 in course of a research project within the Uni-versity of Rostock in Northern Ger-many. The aim of the project was the examination of the injection and ig-nition behaviour of biological special fuels as well as their fit at engine fu-els. Especially the calculation of com-bustion chambers and the design of connection rod geometries for regu-lar diesel engines, when using above named fuels, imply the main interests of the project. Through the years from 1996 to 2000, 20 engine combined power plants were engineered and constructed with a power output up to 2 MW per plant by GMK.

During the operations of the above named com-bined power plants, GMK had been able to indicate the potential of heat en-ergy which remained un-used when given to the environment – even though a large amount of this heat had been used for heat-ing. It was e v i d e n t that back at this time there had been no system on the market that was capa-ble to convert this heat into electricity.As motivated by prior mentioned experiences, GMK focussed, in cooperation with differ-ent universities, onto the development of the ORC process.

Development areasGMK has been focussing on research and develop-ment for suitable working fluids for different applica-tions of the ORC technol-ogy. In these fields of inter-

ests GMK’s engineers and scien-

tists could not only rely on existing

databases, moreover they were in need to determine ex tens ive

knowledge of substantial

data in own laboratories, in

test plants as well as in cooperation with univer-

sities by using high performance computer technology. Based on these thermodynamic equations of state the GERMANIA group is capable to design optimal parameter for every existing temperature frame as well as heat transfer medium for ORC power plants. The company developed in cooperation with the Siemens

Turbomachinery Equipment GmbH, former known as KK&K from Frank-enthal, a special steam turbine for ORC fluids by evaluating the exten-sive knowledge in the area of sub-stantial scientific data. In addition, GMK holds key patents on the steam turbine.

The engineers and scientists at GMK design heat exchangers needed for the ORC process with a weight up to 50 tons. In the research and de-velopment department these heat exchangers are being simulated and optimized with FEM and CFD meth-ods regarding their optimal heat ex-change, pressure resistance and flow guidance. At this basis different ORC plant designs could be realized. All theoretical layouts and engineering work could all afterwards be proven successfully by measurements on run-ning ORC power plants.

Due to the extensive research

and development work, which

had been accompanied by

many scientific papers espe-

cially in the area of working

media and plant- and turbine

layout, key patents had been

registered worldwide.

The latest product from the re-

search and development de-

partment is a small ORC mod-

ule with an electrical power

output of 50 kWel. This IC60

(kVA) module has been de-

signed especially for the elec-

trification of waste heat from

biogas engines. In the year

2009, the first small IC60

power plant of its kind was

commissioned and had been

honoured with the renowned

Ludwig Bölkow technology

award in the same year.

Research Development

Germania Technologieholding GmbH

D-18211 BargeshagenReuterstraße 5

phone +49 3 82 03 / 77 58-0fax +49 3 82 03 / 77 58-20

[email protected]

[email protected]

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