Infrastruktura - Środowisko - Energia
Dodatek promocyjno-reklamowy do "RZECZPOSPOLITEJ".
20 marca 2007 r.
Modern heat and current source in Ostrowski Zakład Ciepłowniczy SA
Renewable source of energy in ORC technology
Works on the preparation of the assumptions for the
project of co-generation source biomass-fired construction lasted since 2004.
The conviction that it is supposed to be the co-generation system existed from
the very beginning, as the predominance of high efficiency of energy included
in the fuel transformation, the decrease of hothouse gases emission as well as
production costs was checked in Ostrowski Zakład Ciepłowniczy SA right after
the implementation of the gas turbo-system with the waste heat boiler in 2000.
Due to the innovatory project character as well as the lack
of national patterns, activities were carried out in terms of aims
determination, the way of implementing innovations, the choice of production
factors combination, the choice of the project variation, the choice of the
capital for the innovation financing. Considerations which were carried out
mostly concerned: variations of technology choice, including the generative
units, location variants with the possibility of using the existing
infrastructure, the influence of the project on the work of the actual district
heating system with regard to the summer season. Different technological system
concepts were analyzed, including:
- With steam boiler fired with biomass and extraction
- With the system of biomass gasification, gas turbine
and/or gas engines,
- With a boiler for thermal oil fired with biomass and ORC
The two subsequent tenders for the design of the steam
boiler fired with biomass and extraction turbine finished unsuccessfully due to
the fact of not meeting the technical requirements and over 40 % exceeding of
the planned project budget.
In March 2005, after the analysis of the hitherto
prevailing tenders, in co-operation with the experts from Ekofundusz, the
assumptions were changed in terms of project costs minimalization. The main
changes include the application of a modern technology ORC (Organic Rankin
Cycle), the usage of the surface in the existing building occurred after the
liquidation of the coal-fired boiler, the usage of the existing technological
infrastructure of EC Ostrów heat and power plant, the acceptance by OZC SA of
tasks connected with the complex project carrying out. The decision was
elaborated by means of economical effective models. The steering in the
innovatory process was directed to the increase of effectiveness. The project
effectiveness calculation was the multiple actions, adjusted for achieving the
Why ORC technology?
The design expects the installation of one boiler for
thermal oil of Austrian company production Polytechnik, with the thermal power
of 9 MWt and oil temperature of 310/250°C, fired with wood silvers. The boiler
in the form of a vertical cylinder is placed by the combustion chamber with
step grate cooled with water, with rusztowinami made of chromium steel. The
effectiveness of the transformation is 79%, and fuel usage - 124 kg/GJ.
Emission parameters: NOx < 400 mg/m3,
SO2 < 400 mg/ m3, CO < 170 mg/m3, dust
< 100 mg/m3.
The heating factor from the boiler, which is thermal oil,
shall be supplied by turbo generator ORC with the thermal power of 7, 3 MW and
electrical power of 1, 5 MW, of Italian production Turboden srl company. The
drawing presents the scheme of boiler for thermal oil co-operation with turbo
generator ORC and thermal network.
Exploitation properties of ORC turbo generator: high
availability (99, 1%), load flexibility (from 10%), almost constant efficiency
in load function (to 40%), serviceless work.
Characteristic features: low pressure and temperature
values, high performance, low thermal tensions, lack of blade erosion, long
life performance, low turbine rotation speed (gear is not present), lack of
water preparation station.
Turbo generator ORC will transmit thermal energy to the
technological system "EC Ostrów" as well as electric energy to the
local energetic system. Electrical energy will be the green energy, so it will
be possible to get the additional income due to the sales of energy production
certificates from the renewable resources. Additionally, it will be possible to
sale the authorizations for emission, achieved as a result of coal-fired boiler
liquidation. Electric energy comprise for 18% of the whole thermal oil energy.
Module ORC with turbo generator will be located in the
existing boiler hall, in the place after the liquidated coal-fired boiler WR
10, whereas the boiler for thermal oil will be placed in the new building,
adjusting to the existing boiler hall. Besides the building for the boiler for
thermal oil, a shed will be built, which will play the function of the biomass
The benefits of the solution:
1. It allows for the usage, in high level, of the existing
on the heat and power plant "EC Ostrów" area infrastructure:
a) Building: using the cubic capacity after the liquidated
b) Technological: connected with the thermal energy output
c) Energetic: usage of the existing SN switching station.
2. It characterizes with beneficial exploitation properties:
a) Yearly heat production - 190 000 GJ,
b) Yearly electric energy production - 10 800 MWh,
c) Yearly usage of bio-fuel - 30 800 t/year (heating value
of 10, 2 MJ/kg),
d) The type of fuel: slivers and bark from the process of
plywood production, slivers from the forest, slivers of energetic willow,
3. It is characterized with the lowest exploitation costs
and the lowest investment expenditure: it is possible to sign the full service contract;
the project budget has closed on the level of 5, 5 million Euros.
4. It shows the highest economic effectiveness. The project
as innovatory one has gained financial support with the subsidy from EkoFundusz
Foundation, which granted money on the level of 40% of project budget. The
project was supported also by NFOŚiGW 20% with preferential credit. The other
own funds OZC SA has been cumulating during the last few years. The calculated
project economical effectiveness shows that the discounted return period is 11
5. The project profitability depends mostly on the average,
yearly amount of working hours as well as the fuel prices. The project
attractiveness increases in case, when there is the demand for heat apart from
the heating period or in case of possibility of gaining cheap bio-fuel, e.g. as
the by-product occurring in the production process. In case when the mentioned
conditions do not take place, the project profitability has to and can be
assured by getting the financing with the grant participation. Nowadays, there
are a few European Union Fund support programs started for investment projects
of local renewable sources.
Heat engineering requires new ways of development
The decrease of harmful emission shall not be only an empty
word. Locally, there is no research carried out regarding the influence of the
harmful emission to the health of the society. There is also no essential
economical reason for using the renewable fuels by the given inhabitants and
heating companies. Only in tourist resorts one can notice the interest in
caring about natural environment. While the project preparations, legislation
changes have started, which promote the protection of the natural environment.
A few times changed energetic law gives lucid support impulses for renewable
resources. The implementation of the act on emissions trade, introduction of
co-generation directive, is another step which shall slowly change the
structure of Polish electro-power industry. National heating system in the
presence of regulatory activities only for a short period of time can receive a
small return from the invested capital. Being mostly in local government
structures it undergoes the influence dependent from the local policy, in
electoral cycles, without care to its infrastructure development. The
investments in heating system are long lasting, capital-consuming and one has
to prepare to the well, using the modern solutions and applying the methods of project
And practically, there is no alternative for heating
companies, which have at their disposal older and older property, than choosing
the scenario which means application of co-generation sources, and especially
renewable sources. Local co-generation sources shall bring measurable savings to
the environment and economical to the heating companies. However, the choice of
the source has to be done properly, with regard to the possibility of selling
the thermal energy in the longest possible period during a year. And
considerable stays the matter of fuel logistics as well as of co-operation with
the local operator of power network. The boiler fired with biomass with turbo
generator ORC is a modern proposal, economically justified, and perfectly signs
in the class of small sources of local power.
The works after project preparation and realization require
a lot of determination, technical knowledge, and risk and at the same time,
caution and organizational abilities. Only a few months have passed from
closing the project financial process and starting its performance.
Construction works aiming at new boiler house have finished. In March, the
assembly of the biomass fired boiler as well as the accompanying devices has
started, whereas in May, the assembly of ORC block shall start. Starting works
of the renewable resource is planned at the turn of III/IV quarter of the
current year, so that, the source could be entered in the heating and power
industry network at the beginning of the heating period. n
Ostrowski Zakład Ciepłowniczy SA
63-400 Ostrów Wielkopolski
tel. (062) 735 86 00