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Published in: Euroheat & Power, Volume, 10/2002 4 water economiser and the hot water boiler in series after the ORC. Following this approach, the ORC can be operated at feed-water temperatures of about 80°C the whole year round, although the feed-water temperature required for the district heating network amounts to 90 to 95 °C in winter. The overall electric efficiency of the CHP plant (= net electric power produced / fuel power input into the biomass-fired thermal oil boiler [NCV]) has been considerably increased by a new and improved coupling of the thermal oil boiler with a thermal oil economiser and an air pre-heater (see Figure 3). Using this approach, the thermal efficiency of the biomass-fired thermal oil boiler reaches 82% (= thermal power output / fuel power input [NCV]), which is about 10% higher than corresponding values from conventional biomass-fired thermal oil boilers [4]. This increased thermal efficiency correspondingly also raises the overall electric efficiency of the CHP plant (= net electric power produced / fuel power input into the biomass-fired thermal oil boiler [NCV]) to about 15% (see Figure 6). 5 Safety aspects, process control and personal demand The high safety aspects of the ORC plant are to be particularly emphasised. All welding seams of the pressure vessels of the ORC plant are 100% X-ray and pressure tested by an approved technical inspection authority (TUEV), which also implies, according to the European pressure vessel regulations, that no repetitions of the tests over the whole lifetime of the plant are necessary. Due to strong fluctuations of the fuel quality and the heat demand in a district heating network, an optimised process control system of the CHP plant is of importance. The ORC process itself is controlled by an SPS, which ensures automatic start-up and shutdown procedures (without the necessary presence of an operator) as well as a smooth load control guided by the feed water temperature at the condenser outlet between 10 and 100% of nominal load. Due to this fully automatic operation, the personnel demand is reduced to checking and maintenance work, which does not exceed 5 hours per week on average. Possible malfunctions of the process are visualised, automatically stored and forwarded to the operator via telecommunication. Regarding a constant thermal oil feed temperature, the biomass-fired thermal oil boiler is more difficult to control. As the thermal oil feed temperature directly influences the load of the ORC unit, a newly developed Fuzzy Logic control system for biomass CHP plants has been installed, with the aim of stabilising and smoothening the operation of the biomass combustion plant and, consequently, of the entire CHP plant. This system is in its test phase at the moment. Due to the fact that the biomass furnace is coupled with a thermal oil boiler operated at atmospheric conditions, no steam boiler operator is needed and the steam boiler operation law does not apply. Thus, the personnel costs are reduced in comparison to steam boilers. The silicon oil used as a working medium in the ORC cycle is environmentally friendly (see section 7). Furthermore, due to the favourable thermodynamic properties of the silicon oil, there is no danger of droplet erosion on the turbine blades. As the working medium is flammable, the ORC process is equipped with a special detection system for organic compounds whereby a small amount of air over all the flanges is sucked in and subsequently analysed using a flame ionisation detector. Through this safety measure the ORC is monitored continuously for leaks. 4PDF Image | ORC process integrated in the biomass CHP plant in Lienz, Austria
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