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

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What we do :

• Process design:

Process optimization

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What we do :

• Equipment:

Heat exchangers

Air cooled coolers

And other process

equipment

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What we do :

• Materials:

Titanium

(Super)Duplex

Nickel-Alloy

Inconel

Other exotics

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What we do :

• Systems:

Incl. controls

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What we do :

• Site work: Erection Assembly Start up Commissioning Service

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What we do :

• Service & Maintenance: Upgrading Debottlenecking Inspection Specialist

maintenance for machines operating hazardous materials

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Our focus on innovation:

• Product development

• System solutions

• New technology

Whizz-Wheel® fans

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Area’s for improvement

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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

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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

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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

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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

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VS

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Debottlenecking / Increasing output

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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

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Sensitivity for wind velocity

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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!

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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:

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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

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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