ORC-biomass - ECOCAL®

ECOCAL® stands for "ecological caloric" and describes our organic rankine cycle product line for the electrification of biomass like wood chips, agricultural waste wood and such from the industry. It is the system based on the organic rankine cyle process for a combined heat and power production being capable to cover a range of heat and power devices from an electrical power output of 0.5 MWel on, more efficient and much more economic than the ordinary water steam process (CRC-process).

Comparison of ECOCAL®-organic rankine cycle -technology with the water steam power process

ECOCAL® offers significant advances compared to power plants operating based on the ordinary water steam cycle. for almost a hundred years it has been possible to produce heat and electricity by the combustion of piece wood with the help of steam engines. Such plants are mainly composed of:

  • a firing for solid fuels,
  • a steam boiler for the production of water steam,
  • a machine such as a steam motor or a steam turbine coupled with a generator,
  • and heat or air condensers.

Next to steam powered machines the boiler is the most expensive main component in the branch of steam power device production. Such systems for the production of high pressurized steam are very complex and sumptuous to produce. For the fabrication of steam boilers, steam pipes and steam boiler armatures, very durable, corrosion withstanding and ferritic-martensistic steel or high temperature withstanding austenitic power plant steel has to be used. Additionally, these special parts are only allowed to be mounted by qualified steam power plant assembling companies.

Contrary to the previous, for the production of electricity in ECOCAL®-power plants do not require a steam boiler. Furthermore in organic rankine cycle power plants the maximal pressures amount up to 10 bar. This means that for the production of ECOCAL®- modules ordinary low cost boiler steel can be used. Based on those pre named properties, ORC-power plants are much more cost effective to erect.

Also because of the low pressures in ECOCAL®-power plants they do not have to be supervised by specially trained personnel which leads to a much more economic working of those plants as well.

ECOCAL® ORC-biomass

  • Overview ORC-Biomass power

  • Fuel silo and transport

    The fuel, such as wood chips, gets into the furnace from the silo (1) by help of a scratch chain conveyor (2) and a hydraulic pusher (3).

  • Firing and exhaust system

    The energy source is burned in the furnace (combustion chamber 1). After the exhaust of the burned wood streamed through the thermal oil boiler (2) it is cleaned, conducted by an induced draught fan (4) and flows to the chimney (5) over a flue gas pipe (3).

  • Hydraulic grate

    The ashes as a residual product from the combustion are fed to the ash gate (2) with a hydraulic grate (1).

  • Ash handling system

    After the ash gate the waste product is conducted by the ash handling system (ash gate (1), exhaust cyclone (2), ash removal (3) and ash container(4)). A change of the ash container is needed approx. every 14 days.

  • Primary cycle with thermal oil boiler

    The hot exhaust flows trough the thermal oil boiler (1), where it transfers its energy to thermal oil with a high boiling point and heats it up to a temperature of approximately 350°C (662 °F) – a temperature which is still below the oil’s boiling point.

  • Evaporator-secondary cycle

    Over the evaporator (1) the energy stored in the thermal oil from the primary cycle is transferred to an organic working medium, which is in the secondary cycle (2) of the evaporator. This working medium is a chlorine free, non flammable, non toxic and for the ozone layer safe silicone oil with a low boiling point, which allows an energy efficient relaxation.

    Due to its low boiling point the working fluid expands immediately when charged with hot thermal oil. Afterwards it flows over the fore run (2) to the turbine (3) and passes its energy on to it.

    Simplified it can be said that the decompressed steam leaving the turbine (3) flows into the condenser (5) where it is liquefied. Following the medium is drawn by the condensate feed pump (6) and pressed into the evaporator (1) to close and continue the cycle.

  • Heat supply

    The condensation heat from the condenser (1) is exchanged to the heat grid (2) to serve heating purposes.

  • Electrical energy

    The ORC-turbine-generator-unit (1) converts the heat energy into electric energy which is fed into the open energy network (3) by help of a transformer (2).

Key figures biomass ORC power plants
Electrical power output: 0.25 - 2.0 MW
Thermal power output: 2.0 - 10.0 MW
Operating period: 8,000 h p.a.
Manpower requirements: 0.1 - 1.0 employees