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Generating Electricity with Your Steam System: Keys to Long Term Savings. May 19th, 2010 Industrial Energy Technology Conference Bill Bullock / Andrew Downing – Turbosteam. How Most Power Is Generated. Generating Power With Your Steam System. Rewards. Risks. Electricity Savings

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Generating electricity with your steam system keys to long term savings

Generating Electricity with Your Steam System: Keys to Long Term Savings

May 19th, 2010

Industrial Energy Technology Conference

Bill Bullock / Andrew Downing – Turbosteam




Rewards Term Savings

Risks

Electricity Savings

Lower Emissions

Improved Operating Characteristics (Power Factor, Reliability)

Releases electrical infrastructure capacity

Completion Risk – Installation Done Correctly

Performance Risk – Turbine Maintains Performance Over Economic Life

Operating Risk – Turbine Maintenance


Quantifying the opportunity
Quantifying the Opportunity Term Savings

There is a Pressure Reducing Valve (PRV) in place

There is an opportunity or need to install new boilers

There is a desire to increase energy efficiency


Design considerations
Design Considerations Term Savings

  • Pressure and temperature conditions – factoring in losses from steam piping design

  • Design the turbine to what the pressure will be at inlet, not what it leaves the boiler

  • 10 psig difference at inlet can mean $30,000 or more a year in electric savings

  • Minimize distance from high pressure header to the inlet of turbine


Design considerations1
Design Considerations Term Savings

  • Verify that you have dry and saturated steam. Moisture in steam can destroy your investment

  • 98% quality steam can impact power output by 10% costing you thousands in savings and tens of thousands in repairs

  • Water chemistry is vital to the protection against corrosion


Design considerations2
Design Considerations Term Savings

  • Install a reliably accurate steam flow meter at the proposed tie in for the steam turbine. Measure your annual steam flow.

  • Measure the pressure and temperature at location, don’t assume anything

  • Chose the low cost, best impact equipment

Actual steam passing through PRV, not out of boiler

Use reliable pressure and temperature transmitters such as Spirax Sarco or Rosemount

Recorded Steam flow for 8,760 hours to get an accurate historical trend


Selecting steam turbine
Selecting Steam Turbine Term Savings

Use a systematic approach to turbine sizing to provide the optimal economic solution

Steam Load

Design for peak?

Max kW, penalized on turndown

25,000

20,000

Design for max annual kWh?

15,000

lbs/hr

10,000

Design for baseload?

Max capital utilization

High $/kW

5,000

500

1000

1500

2000

2500

3000

3500

4000

15 minute increments

There is no universal optimum: depends upon capital cost, system operating profiles, energy rates and financial objectives.


Selecting steam turbine1
Selecting Steam Turbine Term Savings

  • Choose a turbine that is going to give you optimal turn down efficiency

  • Match your annual steam flow to the window of operation

  • Understand what happens below and above your turbines performance curve

  • Installing automatic handvalves are recommended for steam flows that vary hourly or even daily


Determine your savings
Determine your Savings Term Savings

Perform an analysis of a before and after based on your historical steam flow


Case study delmonte
Case Study – Delmonte Term Savings

The Del Monte Foods plant is a former tomato processing plant that currently packages fruit.

  • The system consisted of two separate single stage turbines coupled to a dual shafted induction motor

  • Steam flow demand changed based on process requirements. This option gave the lowest cost, highest turn down efficiency.

  • Winter steam flow falls off significantly and summer steam flow increases as the harvest season approaches


Case study delmonte1
Case Study – Delmonte Term Savings

Turbine Designs

  • First turbine designed for a smaller inlet flow to capture more low end steam

  • Second turbine designed for a higher steam flow to maximize kWh production

  • Both turbines couple to a single generator


Case study delmonte2
Case Study – Delmonte Term Savings

Snap shot of savings Calculations

  • First look at steam flows shows a generation of 2,459,664 kWh

  • Customer did not have boiler installed yet, this was part of an expansion. Steam flows were assumed based on historical data from previous years.


Case study delmonte3
Case Study – Delmonte Term Savings

Environmental impact of onsite generation

(Based on EPA eGRID 2007 Data)

  • By reducing their purchase of electricity by 2,500 MWh per year, this project reduces :

    • NOx by 552 lbs annually

    • SO2 by 340 lbs annually

    • CO2 by 612 tons annually

  • This is environmentally equivalent to the annual CO2 released by approximately 146 cars annually


Case study delmonte4
Case Study – Delmonte Term Savings

Key’s to their success

  • They realized they had a potential to generate on site electricity and reduce the annual energy cost

  • A detailed analysis of the potential generation opportunity was completed

  • Installation and integration of the system was completed by a qualified engineering firm

  • Operators were trained in the successful operation of the unit


Case study calgon carbon
Case Study – Calgon Carbon Term Savings

The Calgon Carbon Plant produces a wide variety of activated carbons, with more than 100 types of granular, powdered and pelletized product

  • The system consisted of a single stage turbine coupled to a reduction gear and generator

  • A 22% increase in electricity rates prompted a look at ways to reduce energy costs

  • The steam plant operates a waste heat boiler that produces ~ 50,000 lbs/hr of steam for ~ 8,400 hours per year.


Case study calgon carbon1
Case Study – Calgon Carbon Term Savings

Snap shot of savings Calculations

  • Calgon Carbon installed flow meters to measure hourly steam flow for an accurate generation model

  • Taking into account enthalpy lost through the turbine, calculations were made for make up steam

  • Annual generation at ~ 5,422 MWh’s, saving more than $300,000


Case study calgon carbon2
Case Study – Calgon Carbon Term Savings

Environmental impact of onsite generation

(Based on EPA eGRID 2007 Data)

  • By reducing their purchase of electricity by 5,422 MWh per year, this project reduces :

    • NOx by 5 tons annually

    • SO2 by 8 tons annually

    • CO2 by 3,014 tons annually

  • This is environmentally equivalent to the annual CO2 absorption by approximately 362 acres of trees


Case study calgon carbon3
Case Study – Calgon Carbon Term Savings

Key’s to their success

  • Electricity rates were increasing, and being proactive, they found a solution to offset their purchased energy

  • Installation of measurement equipment to accurately measure steam flow for 12 months

  • The staff was motivated to constantly seek out and identify cost saving opportunities, to protect sales margins against increasing competition from China and from cost of operation increases


QUESTIONS Term Savings


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