ORC ElectraTherm Green Machine - waste heat to power, Power generation

solution for renewable and green energy
BIOGAS STATIONS
Utilization of waste heat and process heat from BGS with the use of the Green Machine

WhatistheGREENMACHINE?
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
twinscrewexpander.TheGreenMachineproduceselectricity,which
is transformed from a source of low-temperature waste heat from
BGScogenerationunits,andoffersaverygoodreturnoninvestment.

GreenMachineUnit
Green 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
kWe
Hot
Water
°C
Thermal
input
kW
Flow rate
l/s
Hot
Water
°C
Ambient air
temperature
°C
Condensation load
kW
20–65 77–116 400–860 3,8–12,6 4–43 < 38 380–795
Hot water to power* in metric units
PERFORMANCE PARAMETERS
* gross production

WorkingprincipleoftheGREENMACHINE
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.

SchematicdiagramoftheprincipleoftheGREENMACHINEfunction
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

PatentedScrewExpander
The 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.

StandartizedconnectionofCHPJenbacherandGreenMachine
94 kW
59 kW
75,0 °C 78,4 °C 88,5°C
98,6 °C
max. 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 1st
phase
Hot water circuit (calculated with 37 % glycol)
Cooling circle(calculated with 37 % glycol)
Usable thermal output
Project 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

StandardizeddiagramofintegrationoftheGreenMachine
JMS 412 GS-B.L
Version B25
Pel=889kW
Pm=916kW
C
J I
D
B
A
N
M
≤1,3m
H
MAX. ΔT 10°C/MIN
MAX. ...BAR
MIN. 2,5BAR
Qww
F
F
Lp
Maf
Qag
01
P.01-YFA-101
P.06-YPS-001
P.06-YFC-003
P.06-YTC-001
P.06-M-001
P.06-P-001
P.06-B-001
P.06-YPC-001
P.06-W-101
...×
...kW
...A
...V
...Hz
P.06-W-001
P.06-YTC-002
DN125/DN100
DN125 / DN100
P.02-W-001
P.02-XSA-001
...×
...kW
...A
...V
...Hz
ORC
ARI-EURO-WEDI-DN80
DN100
DN100
2,5 bar
DN 80
DN 80
PITI
TI
80 l
G1/2
4 x DN 65
PN10
DM28
PN10
DM28
[..-..]
Δp MN = 0,8bar MAX.
150mbar AH
SL
DN125
PN16
JES
PN16
DN125
PN10
DN100
PN10
DN100
.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
PN10
DN65
55,0°C
PN10
DN65
DN300
PN10
650°C AH
JES
JES
99°C ASH
ASH
5bar ASH
2,5bar ASL
JES
JES
JES
JES
93,2°C
90,0°C
180°C AH
JES
424°C
58,1°C
Δp=.bar
Δp= .bar
JES
.
Sheet.
.
Sheet.
.
Sheet.
.
Sheet .
III
III
.
Sheet .
III
.
Sheet .
.
Sheet .
.
Sheet.
.
Sheet.
JES
JES
JES
JES
JES
JES
JES
JES
JES
PS
P.01.103
US
P.01.101
PDS
...
PS
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.06.015
TI
P.06.015
PI
TI
P.02.008
PS
P.06.001
TS
P.06.001
PI
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
.L
.L

TechnicalprioritiesoftheGreenMachine
Priorities 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.

PLCpanelGreenMachine
remote monitoring
+ control

WhytoconnecttheGreenMachine
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

BasicinformationaboutinstallationoftheGreenMachine
Location:
BGS Moravská Třebová
Czech Republic
1 pc Green Machine 50 kW
operating 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

Investor:
Fosfa, a. s.
Břeclav-Poštorná, Czech Republic
Cogeneration unit for burning natural gas
Cogeneration unit: Tedom 2 × 500 kW

Location:
BGS Vysoké Mýto
Czech Republic
Cogeneration unit: Schnell 4 × 250 kW

Location:
BGS Brno
Czech Republic
Cogeneration unit: Schnell 4 × 250 kW

Location:
BGS Zemplínská Teplica
Slovak Republic
Cogeneration unit: Jenbacher 1036 kW

Location:
BGS Strážnice
Czech Republic

Location:
BGS Šlapanov
Czech Republic

Location:
BGS Trechwitz
Germany
Cogeneration unit: MWM 1000 kW

Location:
BGS Bohmte
Germany

inconnectionwiththeoperationofthe
GreenMachineatBGSandCHP
ECONOMICBENEFITS
OFTHEGREEN
MACHINE

ControlmeasurementofhourlyoutputandefficiencyofCHP
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

Test carried out on 27/02/2013, CHP – Jenbacher, ambient temperature 4–6°C
Installed
capacity of
CHP
Efficiency
of CHP
(%)
889 kW 100,00
CHP – production
of electricity without
the Green Machine
Efficiency
of CHP
(%)
823,2 kW 92,6
CHP – production
of 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 (%)

BGS Strážnice – output of CHP (excerpt from the basic technical conditions)
TechnicaldescriptionofCHP–JenbacherJMS412GS-B.L
Standardized referential conditions:
Air pressure 1000 mbar or 100 m a.s.l
Air temperature 25 °C or 298 K
Relative humidity 30 %
Volumetric data in the normal state
(combustion gas, combustion air and flue gas):
pressure of 1013 mbar
temperature 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

RETURNPAYBACK
OFINVESTMENTS
amodelcase
newinstallationsatBGS

AmodelexampleofthepotentialforinstallingtheGreenMachine
BGS – 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

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 kW
CHP 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 temperatur
in Germany
5 kW
Consumption at the average temperature
in 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

ELECTRICALOUTPUT
ANDREVENUES
anexamplecase
newinstallationsatBGS

AmodelexampleofassumedelectricaloutputsoftheGreenMachine
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

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

ServisplanFORTHEGREENMACHINE
standardserviceoperations

Two-year plan of servicing operations for the Green Machine
1st 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
PlanofservicingoperationsfortheGreenMachine

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™

ORC ElectraTherm Green Machine - waste heat to power, Power generation

ORC ElectraTherm Green Machine - waste heat to power, Power generation

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