Zuccato Energia - Model ZE-200-LT - 200-KWE
Technology
Zuccato Energia systems are based on the organic Rankine cycle (ORC), a thermodynamic cycle high efficiency which has ideal characteristics for the conversion of electrical energy sources of thermal energy at low-medium temperature (from 86 ° C).
Functionality:
The heat (1) is conveyed to a heat exchanger (2) called an evaporator, which heats a low-boiling-point working fluid that expands spinning a turbine (3) attached to an alternator generating electric power (4).The working fluid is then condensed in a condenser heat exchanger (5) and residual heat is dissipated by using an external cooling system such as an evaporative cooling tower or a dry cooler.
High-Performance
Independently designed and manufactured using the most advanced technologies in finite elements and fluid-dynamics analysis (CFD/CFX), ZE turbogenerators are designed from scratch to operate in a low-temperature organic Rankine cycle which uses a special working fluid that offers better performances and several advances over traditional steam turbines:
- Low operational temperature which allow our systems to tap even low-grade heat sources;
- High condensation temperature which may allow the use of simple air-cooled condensers;
- Totally dry working fluid, which means no turbine blade erosion, giving the system high reliability and reduced maintenance costs as well as fewer controls;
- Lower operational pressures (20 bar max), which mean safer operation, less bureaucratic prodlems and reduced plant costs;
- No atmospheric emissions (closed circuit operation);
Environment- Friendly
From an environmental standpoint, ZE systems are reproachless:
- They recover otherwise wasted resources such as waste heat and byproducts or help tapping renewable sources such as solar and geothermal heat;
- They use plain tap water for thermal energy transfer instead of environmentallydangerous diathermal oil;
- Their working fluid is ozone-friendly, non-toxic, non flammable in liquid form, and 100% biodegradable;
- They are made of recyclable, environmental friendly materials, use a minimum of plastic parts and employ no toxic substances in their construction.
ORC Circuit Components
Besides the aforementioned working fluid, the power generation module is made of various elements, shown in the following diagram.
Turbine and Generator
The following tables show the main technical specification of the ZE-200-LT power generation module turbine and its attached generator and inverter.
Turbine
- Type: Single-stage radial inflow turbine w/fixed nozzles, directly coupled to generator shaft
- Operating Temperature (input/Output): 145°C/~100°C
- Stage pressure: PS 16 (tested to 24 bar)
- Materials: Machined steel [body) / Aluminium alloy ompeiieo
- Speed control: Feedback loop on the generator current output
- Seals and gaskets: Sealed labyrinth on impeller back and optionally at generator interface. Environmental seal using gaskets and O-rings
Generator
- Type: Synchronous, permanent magnet
- Power Output: 200 kWe
- Rotational Speed: 15.000 Rpm(12...18 kRpm)
- Rectifier /synchronizer: Built-in/Included
- Cooling system: Water jacket
- Cooling fluid: Water + glycol mix @ Tih
Inverter
- Type: IGBT- mains synchronized
- Output power: 100kWe
- Output voltage: 400V+5%Tol.
- Output frequency: 50Hz+0,5%Tol.
- Cooling: Air-cooled
- Max operational environmental temperature: 40'<
- Braking chopper: Built-in, 200 kW
System Components
The heat exchangers used in this power generation module are of the brazed plate type - the most compact and efficient solution for several applications. Made by brazing several quality corrugated steel plates together, taking care first to turn the fishbone-shaped corrugations on each plate 180° from the next one, these exchangers have very small fluid-passing sections, so their heat exchange-to-encumbrance ratio great. Their most important characteristics are:
- Small size : they occupy down to 10% of the space other exchanger types require, making transport easier and the plant smaller.
- Low temperature differentials: they can work with minimal temperature differences between cooling fluid and cooled fluid, thus increasing overall system efficiency;
- Low load losses: in most cases, even lower than those of a coaxial exchanger.
- Resistance to dirt and corrosion: high fluid turbulence and total use of the available surface means a drastic reduction in deposits due to material contained in the fluids. What’s more, they may be perfectly cleaned using normal detergent fluids. Corrosion problems are avoided by using specifically resistant materials in their construction.
Heat Exchangers
- Type: Brazed plate
- Working pressures: 30 bar (Nominal)/ 39 bar (Test)/225 bar (Burst)
- Construction materials: AISI316 S/Steel& 99,9% copper
- Max working temperature: 195°C
Condensation Tank
Required to keep an adequate reserve of liquid working fluid for the plant, it is made of rustproofed carbon steel with PN25 connections, has a capacity of 180 litres and is equipped with a built-in level sensor.
Working Fluid Pump
Required to make the condensed working fluid flow back into the ORC loop, its motor is of the closed short-circuited cage type with external ventilation . Energy-efficient (class I), it has IP55 protection and is certified to the EN 60034-1 standard. Equipped with class F insulation (Tmax=155°C), its hydraulic part is kept in place between the upper cap and the pump body by tie rods.
Control Panel
The control panel hosts all control, supervision, automation and communication electronics for the power generation module. It contains :
- Process management electronics;
- Temperature and pressure control electronics;
- Alarm management systems;
- Mains connection systems and inverter circuitry for power factor correction;
- Mains interface panel with low-voltage protection circuitry.
The control panel also include a built-in cellular modem router that allows password-protected, policy-regulated remote access and system control through the Internet.
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