Post on 26-May-2015
description
ICCI 2014 FACS - 26/4/2014
Dynamic Heat Exchange SolutionsAir-cooled coolers & debottlenecking, reduction of plot
space, noise and energy consumption
Femke Schaëfer-Wering
Istanbul – April 26th , 2014
ICCI 2014 FACS - 26/4/2014
Topics:
• Short introduction to Bronswerk Heat Transfer®
• Improvement area’s for energy efficiency
• Case studies
ICCI 2014 FACS - 26/4/2014
Introduction
ICCI 2014 FACS - 26/4/2014
ICCI 2014 FACS - 26/4/2014
Our markets:
Sustainability Service & Maintenance
Power
Oil
Gas
Chemical
Air Handling
Food Processing
ICCI 2014 FACS - 26/4/2014
ICCI 2014 FACS - 26/4/2014
ICCI 2014 FACS - 26/4/2014
What we do:
• Thermal designs:
based on:
Aspen/HTFS
HTRI
HEI
Computational Fluid Dynamics
Hysys
ICCI 2014 FACS - 26/4/2014
What we do:
• Mechanical designs:
- ASME
- EN13445
- AD2000
- RTOD
- PD5500
- CODAP
- GOST
FEM analysis
ICCI 2014 FACS - 26/4/2014
What we do :
• Process design:
Process optimization
ICCI 2014 FACS - 26/4/2014
What we do :
• Equipment:
Heat exchangers
Air cooled coolers
And other process
equipment
ICCI 2014 FACS - 26/4/2014
What we do :
• Materials:
Titanium
(Super)Duplex
Nickel-Alloy
Inconel
Other exotics
ICCI 2014 FACS - 26/4/2014
What we do :
• Systems:
Incl. controls
ICCI 2014 FACS - 26/4/2014
What we do :
• Site work: Erection Assembly Start up Commissioning Service
ICCI 2014 FACS - 26/4/2014
What we do :
• Service & Maintenance: Upgrading Debottlenecking Inspection Specialist
maintenance for machines operating hazardous materials
ICCI 2014 FACS - 26/4/2014
Our focus on innovation:
• Product development
• System solutions
• New technology
Whizz-Wheel® fans
ICCI 2014 FACS - 26/4/2014
ICCI 2014 FACS - 26/4/2014
Area’s for improvement
ICCI 2014 FACS - 26/4/2014
One: Newbuilds
Start at the design: reducing energy consumption of process equipment
Fans of the air cooled coolers,
condensers & combustion blowers
Pumps/compressors
Our high efficiency fans reduce
energy consumption by 50%
Our high efficiency pumps/
compressors reduce energy
consumption by 20-40%
ICCI 2014 FACS - 26/4/2014
Two: Upgrading of Installation
High efficiency fans & pumps: increase plant capacity and efficiency
Approx. 200 kW per condenser
Approx. 600 kW combustion
blowers
Approx. 1000 kW pumps
Use these kW’s more efficiently
Increasing output
ICCI 2014 FACS - 26/4/2014
Overall Plant Performance
Improve plant efficiency; increasing the overall efficiency by 6%
The plant efficiency is approx. 30-40%
2% is used for fans of the
condenser
6% is used for the fans of the
combustion blowers
Saving 50% on fan power
10% is used for pumps
Saving 20% on pumping power
Increase overall efficiency by 6%
ICCI 2014 FACS - 26/4/2014
Case studies
ICCI 2014 FACS - 26/4/2014
Current situation:
•Huge plot space requirement
•High power consumption for air coolers
•Big influence on CAPEX & OPEX
Case study 1 – High efficiency cooling
ICCI 2014 FACS - 26/4/2014
Case study 1 – High efficiency cooling
•New fan design based on
aerospace technology
•Intensified heat transfer
•Over 50% reduction in
power consumption
•OR
•Over 30% plot space
reduction
ICCI 2014 FACS - 26/4/2014
Original design based on standard air coolers;
• Absorbed electrical power: 1143 kW
• Plot space used: 4224 m²
• Noise power emission: 101 dB(A)
Case study 1 – High efficiency cooling
ICCI 2014 FACS - 26/4/2014
Improved design based on high efficiency air coolers (with Whizz-Wheel® fans);
Old New
• Absorbed electrical power: 1143 kW 528 kW
• Plot space used: 4224m² 2974 m²
• Noise power emission: 101 dB(A) 94 dB(A)
Case study 1 – High efficieny cooling
ICCI 2014 FACS - 26/4/2014
Benefits;
• Noise reduction: 7 dB(A)
• Size reduction: 1250 m² = 29%
• Power consump. red.: 615 kW = 53%
• Opex savings: € 492.000,- / yr
Figure 3: comparative
Figure 2: high efficiency designFigure 1: standard design
Case study 1 – High efficiency cooling
ICCI 2014 FACS - 26/4/2014
VS
ICCI 2014 FACS - 26/4/2014
Debottlenecking / Increasing output
ICCI 2014 FACS - 26/4/2014
Case study 2 – Debottlenecking/ Increasing output
• 35% more cooling air
• 10-15% more production
• € 700 million gas production
• € 70 million additional
• Debottlenecking investment: € 5,5 million
ICCI 2014 FACS - 26/4/2014
Case study 2 – Debottlenecking / Increasing output
Restrictions:
• Maximum noise level
• Production capacity
down to 60%
Results:
• Elimination of all
noise issues
• Production up to
100%
Bonus:
• 56% savings in
energy consumption
ICCI 2014 FACS - 26/4/2014
Case study 2 – Debottlenecking/ Increasing output
Restrictions:
• Lower noise level or
plant shut down!
Results:
• All 65 fans installed
• Elimination of all
noise issues
Bonus:
• 53% savings in
energy consumption
ICCI 2014 FACS - 26/4/2014
Sensitivity for wind velocity
ICCI 2014 FACS - 26/4/2014
Current situation:
Steam turbine condenser:
Power consumption: 1200 kW
Opex: € 768.000,- / yr
Performance testing for air cooled
condensers based on official guidelines
Average wind speed should remain
under 3 m/s
Maximum Beaufort 2
At higher wind speeds no performance
guarantees
In most cases there’s more wind!
ICCI 2014 FACS - 26/4/2014
Case study 3 – Sensitivity for wind velocity
Two solutions:
Larger cooler with low energy consumption fans
Slight breeze
Negative effect on operation of the fans
Negative effect on condenser vacuum
Generating less electricity to the power grid
Same cooler with more air because of high efficient cooling Reduce effect of crosswinds
ICCI 2014 FACS - 26/4/2014
Case study 3 – Sensitivity for wind velocity
Case study 3 – Sensitivity for wind velocity
Benefits:
Lower power consumption in majority of operating conditions and
seasons:
Additional bonus: over 50% savings on energy consumption:
€ 384.000,- /yrICCI 2014 FACS - 26/4/2014
Case study 3 – Sensitivity for wind velocity
Wind effect on yield
Air quality (%) in: < 3 m/s 5 m/s 7 m/s
Beaufort < 2 3 < 4-5
Conventional design 100 77.5 49.2
High Efficiency 100 91.6 79.2
Future perspective for gas evaporation plants
ICCI 2014 FACS - 26/4/2014
Source: Siemens USA
FACS - 14/10/2013LNG Tech Global Summit 2013
Case study 4 - Regasification
Original design based on conventional fans
• Nr. of fans per vaporizer:` 4
• Diameter fan: ca. 1 m
• Design flow: 108 m3/s
• Design Δp: 150 Pa(nom.)
• Absorbed vaporizer power: 45 kW
FACS - 14/10/2013LNG Tech Global Summit 2013
Case study 4 - Regasification
Case study 4 - RegasificationRedesigning the air heated vaporizer with the Whizz-Wheel®
Improved design based on Whizz-Wheel® fans
Option 1: reduced energy consumption
• Nr. of fans per vaporizer: 1
• Diameter fan: 3 m
• Design flow: 108 m3/s
• Design Δp: Whizz-Wheel®
• Absorbed vaporizer power : ~10 kW
• Reduction in energy consumption: > 70%
FACS - 14/10/2013LNG Tech Global Summit 2013
Case study 4 - RegasificationRedesigning the air heated vaporizer with the Whizz-Wheel®
Improved design based on Whizz-Wheel® fans
Option 2: reduced plot space
• Nr. of fans per vaporizer: 1
• Diameter fan: 3 m
• Design flow: 216 m3/s
• Design Δp: Whizz-Wheel®
• Absorbed vaporizer power: ~ 45 kW
• Reduced plot space: 50%
FACS - 14/10/2013LNG Tech Global Summit 2013
Case study 4 - Regasification
Redesigning the air heated vaporizer with the Whizz-Wheel® fan
Benefits:
• More air flow: (2x)
OR
• Reduced power > 70%
OR
• Lower number of vaporizers: 50%
• Weight reduction (offshore): 50%
• Reduced plot space: 50%
• Cost saving on piping, cabling: 50%
FACS - 14/10/2013LNG Tech Global Summit 2013
Summary
Yes, Bronswerk Heat Transfer can help your power plant become more sustainable and profitable at the same time:
ICCI 2014 FACS - 26/4/2014
Air Cooled Coolers & Efficiency
Reduction of energy consumption Power consumption reduction up
to 50%
Reduction of plot space Or up to 30% in plot space area
Debottlenecking Reduced effect of crosswinds and
higher yield
Reduction of noise Noise reduction 4-6 dB(A)
Thank you for your attention.Questions please
ICCI 2014 FACS - 26/4/2014
How to contact us:
www.bronswerk.com
facebook.com/bronswerk
Linkedin.com/company/bronswerk-heat-transfer
twitter.com/bronswerk
And come visit our booth in the central hall
ICCI 2014 FACS - 26/4/2014