Temadag DTI Løsninger til energibesparelser og reducering af CO2 udslip i dampsystemer. Thomas Maurin, Teknisk Chef Danmark & Sverige

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1 Temadag DTI 2012 Løsninger til energibesparelser og reducering af CO2 udslip i dampsystemer Thomas Maurin, Teknisk Chef Danmark & Sverige

2 Spirax Sarco Ltd mennesker i mere end 30 lande, der alle arbejder med samme ide: Energi og miljørigtige løsninger! Europa betjenes primært fra England, Frankrig og Italien. Forskningscenter i England Egne afdelinger for at kunne kommunikere det væsentlige: Energibesparelser og reducering i CO2 udslip!

3 Spirax Sarco Danmark 18 personer 4 eksterne salgsingeniører der kan dække hele Danmark Intern salgssupport Teknisk support Lager og værksted Serviceafdeling, 4 serviceingeniører, drift og vedligehold, energiaudits, gennemgang vandudladere, positionerer og andre energiforbrugene udstyr. Rådgivning til kunder og rådgivere. Hjemmeside:

4 Det moderne dampanlæg Langt de fleste fabrikker oplever et stigende pres for at reducere deres energiforbrug og CO2 udslip For at imødekomme disse krav må vi have nogle simple løsninger Den moderne fabrik burde ikke opleve flashdampspild eller lukke varmt vand ud i kloakken Det skal opsamles og genanvendes Genanvendelsen bør altid kunne forbedre effektiviteten I processen

5 Største områder med energitab Flashdamp tab Varmetab fra forurenet vand Varmetab fra køletårne Varmetab fra proces udluftning Varmetab fra forurenet kondensat

6 Hvad er damp? Entalpi kj/kg Damptryk Temperatur Væskevarme Fordampningsvarme Total varme Volumen tør mættet bar kpa ºC hf hfg hg m 3 /kg , , , , , , , , , , , , , , ,132

7 Hvad er flashdamp Hvad er flashdamp (også kaldet genfordampning)? Flashdamp opstår når kondensat ledes fra et højere tryk til et lavere tryk og derved vil noget af det genfordampe. Ved atmosfærisk tryk kan vand ikke eksisterer ved mere en 100 C - dvs. kommer kondensatet fra 180 C skal der afgives 80 C og det sker ved genfordampning eller flashdamp! Hvis denne flashdamp ikke udnyttes opstår der et varmetab ud gennem den nærmeste udluftningsledning Det samme sker når der bundblæses fra en dampkedel (8 barg / 175 C). Her vil der også være et kortvarigt varmetab, som man skal forsøge at genanvende

8 Hvad er flashdamp kg/h Væskevarme 743 kj/kg Fordampningsvarme kj/kg Væskevarme 506 kj/kg 8 bar g, 175 C 1 bar g, 120 C Regnestykket: Fordampende væskevarme = kj/kg = 237 kj/kg 237 kj/kg x 100 = 10,7 % Flashdamp 1000 kg/h x 0,107 = 107 kg/h Flashdamp kj/kg 107 kg flashdamp svare til 65 kw!

9 Flashdamptab 8 barg dampforsyning 86 % Kondensat Retur til dampkedel 14% flashdamp I det perfekt dampanlæg skal der ikke spildes noget flashdamp og kondensatet skal returneres så tæt på kogepunktet som muligt til dampkedlen Opvarmning af procesvand Opvarnning af procestank Kondensatpumpe

10 Løsninger til udnyttelse af flashdamp

11 Adskillelse af flashdamp fra kondensat via flashdampbeholder Kondensat / flashdamp ind Flashdamp Kondensat ud Adskiller dampen og kondensatet i kondensatrøret. Genfordampningens maksimale fremløbshastighed i tanken er 3 m/s. Takket være den lave fremløbshastighed i tanken adskilles dampen og kondensatet godt. Kondensat falder til bunds og dampen strømmer opad. Kondensat udledes fra tanken vha. en svømmervandudlader.

12 Hvor kan flashdamp udnyttes? Typiske anvendelsesformål: Opvarmning af brugs- og procesvand Procesopvarmning Opvarmning af fødevand Forvarmning af luft Luftbefugtning

13 Flashdamp Condenser Venthead- Returnerer 70% af de frie vandpartikler Udluftning til det fri Procesvand ud (varm) Procesvand ind (kold) Kondensat retur Flashdamp Kondensat og flashdamp ind

14 Flashdamp Condenser, Principskitse

15 Løsninger med optimal energiudnyttelse

16 Udnyt dampen bedst muligt Kondenser dampen ved lavest muligt damptryk/temperatur Her har du højeste energiindhold pr. kg. damp der kondenseres Dimensioner varmeveksler så der ikke opstår flashdamp. Men vær opmærksom på drænløsningen Færre belægninger (mindre service) Entalpi kj/kg Damp tryk Temperatur Væskevarme Fordampnings -varme Totalvarme Volumen tør mættet bar kpa ºC h f h fg h g m3/kg , , , , , , , , , , , , , , ,132

17 introducing the new Spirax EasiHeat incorporating SIMS technology

18 the new Spirax EasiHeat HTG & the new Spirax EasiHeat DHW

19 meeting the challenge of managing energy costs Spirax EasiHeat HTG a complete, compact, ready to use steam to water heat transfer package with innovative monitoring system delivers superior energy efficient performance lowers costs, tackles waste and mitigates environmental impact programmable timer further increases efficiency touchscreen SIMS technology as standard

20 the more energy efficient alternative Benefits Spirax EasiHeat HTG energy efficient helps reduce costs and reduces CO 2 components precisely sized to provide optimum performance compact core unit occupies on 1.8m 3, up to 3.9m 3 for the largest output unit low cost of ownership high quality low maintenance components reduce maintenance, and seldom requires annual insurance inspection quicker, easier installation

21 the more energy efficient alternative Spirax EasiHeat HTG features a 7 day programmable time clock so you can have your system on only when needed outside weather compensation autoadjusts the heating set point, so if the outside temperature rises the system will lower its temperature output advanced control method further improves energy efficiency and maintains a comfortable working environment

22 meeting the challenge of managing energy costs Spirax EasiHeat DHW a complete, compact and energy efficient heat transfer solution delivers constant supply of domestic or process hot water at a stable temperature on demand even with sudden load changes reduces energy costs, tackles waste, and mitigates environmental impact touchscreen SIMS technology as standard

23 the more energy efficient alternative Benefits Spirax EasiHeat DHW energy efficient helps reduce costs and reduces CO 2 instantaneous hot water without storage reduces energy loss, reduces risk of Legionella growth compact core unit occupies on 2m 3, up to 3.8m 3 for the largest output unit

24 the more energy efficient alternative Spirax EasiHeat DHW High quality, low maintenance components reduce maintenance costs Seldom requires an insurance inspection due to the very low volume of the heat exchanger No storage or buffer tanks - eradicates a potential breeding place for bacteria, reducing the need for regular inspections

25 the more energy efficient alternative Spirax EasiHeat DHW The graph illustrates the performance of the Spirax EasiHeat DHW on instantaneous duty. The application is water heating, with a high secondary temperature rise and large sudden load changes; a duty typical of process hot water. The graph shows that even with the large sudden load changes, a safe, constant hot water temperature is maintained.

26 Spirax EasiHeat key features no waste design compact design touch screen control unique Spirax intelligent control pre-assembled tested unit integrated communications

27 Introducing SIMS technology

28 Spirax EasiHeat incorporating SIMS technology SIMS technology is the new energy monitoring system which allows interrogation of energy, CO 2 and carbon data from any location. A wide number of communication protocol options provides the Spirax EasiHeat with the flexibility to integrate with many existing communication and building management systems.

29 S.I.M.S technology key features 7 colour, intuitive touch screen control with advanced graphics as standard Complete visual access to all parameters. Easy to interrogate and obtain the required data No complex controls SIMS technology can be operated with limited previous controls & instrumentation experience Access and control from any location, globally Compatible with Ethernet, Modbus, Profibus, CANopen, EtherCAT and many more Optional web server allows secure remote access to monitor and control the unit via standard web browser Generates text or alerts if an event occurs or as a service reminder

30 Rengøringssystem UDEN varmtvandsbeholder Energi og CO2 besparende EasiHeat Udtag til spuleslanger Damp ind 100% Kondensat retur til kedel (ingen flashdamp) Automatisk Pumpe/vandudlader Cirkulations pumpe Vandpåfyldning

31 Energi og CO2 besparende varmeveksling Sizing Suite Program Tilbagebetalingstid kan blive meget attraktiv! Jo mere du bruger den mere du bruge vekslerunitendesto hurtigere betaler den sig hjem

32 Ny energibesparende Easiheat - Priseksempel Type EHD3PPNPT-HLG1-ER1: Pris kr ,00 High limit APT14 Dampmåler (energimåler) SIMS teknologi: Level 1; SMS + Varme Facts Dampforbrug: 753 kg/h (Normalt 857 kg/h) Årlige driftsbesparelser: kr. (i forhold til ikke - energibesparende løsninger) Energitilskud v/25 øre pr. kw: x 0,25 = kr. Tilbagebetalingstid Salgspris inkl. tilskud: = kr. Tilbagebetalingstid: / = 4,2 år

33 Løsninger med effektiv varmeveksling af returkondensat

34 ICHRU Inline Condensate Heat Recovery Unit Vahterus brochure Procesvand (kold) Procesvand (Opvarmet)

35 ICHRU Inline Condensate Heat Recovery Unit

36 ICHRU Installationseksempel ICHRU

37 Standard FREME Unit Prisvindende! 37

38 Standard FREME Flash Recovery Package: Boiler Application Cooled condensate to deareator By-pass line Feedtank and deareator Tank water To feedpump Boiler Heated return From FREME Condensate return By-pass valve FREME Flash Condensing Package

39 Standard FREME Flash Recovery Package: Boiler Feedwater Heater Sensor Condensate Bypass Vent Condensate Return FREME Flash Recovery Skid Condensate Pump returning cooled condensate and heated water to boiler Mixing Manifold Temperature control Valve Water Softener

40 Standard FREME Unit: Procesvandsforvarmer Procesvandsføler By pas for kondensat Opvarmet procesvand Procesvand Bufferank Afkølet Kondensat Kondensat retur Niveaureguleringsventil Kondensatpumpe Standard FREME unit Kold procesvand

41 Konfigurering af FREME Unit

42 De Mulder - cuts energy costs by 20% De Mulder & Sons in Nuneaton is a by-product processing plant A flash steam recovery system is delivering direct energy savings of 10%, plus a further 10% of indirect savings 42

43 External Heater replacing heating coil or direct injection on Process Tank Low Carbon Easiheat Hot Water Exchanger Package Process Tank Steam Supply Circulating Pump No overflow to drain 100% Condensate Return to boiler

44 Heat Recovery from Effluent

45 Problems associated with hot effluent going to drain High quality energy going to drain Effluent contaminated with solids Effluent treatment costs Cold water on re-fill of process Longer heat up times. Start up can cause boiler priming or lockout Steam starvation on heat up can cause quality problems elsewhere in plant

46 Effluent Heat Recovery system Control Panel Flow balancing valves Self cleaning filter Heated process water Hot Effluent from Plant Dump Valve Cold back flush Cooled effluent To drain Cold process water

47 Process Plant with Effluent Heat Recovery System 47C Hot water to plant Heated process water holding tank 50C Effluent recovery skid Cold Make-up water Easiheat process water Boost packages with 100% condensate return Hot effluent sump

48 Heinz saves?? a year Heinz saving 1,500 kw on heat recovery package It s been in place for 18 months now and we are seeing excellent results from the heat recovery, Barry Aspey Utilities Manager for Heinz

49 Heat Recovery from Cooling Towers

50 Losses from Cooling Tower Heat Recovery Electrical running costs from cooling tower fans Vapour loss from cooling tower Heat normally lost at cooling tower Chemical dosing of cooling tower Flash losses from water heaters

51 Cooling tower heat recovery system Heated water storage tank Reduction in vapour loss Reduction in Fan electricity Cooling Tower 100% return Easiheat boost To wash down system Heated process water Hot water from retort or cooling system 100% return Cooling water Recovery exchanger Cooled water to plant Easiheat boost to process water Cold process water

52 Heat Recovery from Process Vents

53 Heat recovery from process vents No vent loss Vent condenser system Vapour vent system Heated water to tank Final temp Process water to plant Vent drain Cooking vessels Cold process water Easiheat Boost Exchanger Package Pre-heated water storage tank

54 Heat Recovery from Contaminated Condensate

55 Contaminated Condensate Normally dumped to drain May contain contaminates not suitable for the boiler feed Condensate flashes off at point of discharge Remaining condensate at boiling point Must be cooled to 42C before entering drainage system Usually operates 24/7 A large loss of energy and CO2

56 Heat Recovery from Contaminated Condensate Process vessels with contaminated condensate APT Packages Sealed condensate return Process Water tank FREME Flash Package Cooled contaminated condensate To drain

57 Løsninger til dampdistributionen

58 Energibesparelser ved dampdistribitionen Vandudladerkontrol 2 gange årligt Reducere dampspild, energispild og CO2 udledning Forbedret varmeoverføringseffekt Gennemsnitlig tilbagebetalingstid. 4 måneder!

59 Standard vandudladerstation Messing kontraventil Sorte nippelrør Bronze afspærringsventil SG-jerns vandudlader Bronze afspærringsventil SG-jerns vandudlader 10 Potentielle lækage steder 5 Komponents skal installeres Multible materialetyper

60 Moderne vandudladerstation All stainless welded construction ( no leak paths) Stainless steel ball valve Quick fit stainless steel trap with in-built filter Stainless steel ball valve Stainless steel check valve

61 Konklusion Disse er kun nogle få af de tilgængelige løsningerne Systemerne kan leveres i samlede enheder for at lette installationen og eliminerer installationsfejl Reduktion af energiforbruget og CO2 i anlægget er let opnå og der kan oftest opnås attraktive tilskud til de energibesparende installationer Procesforbedring opnås altid Besøg for flere løsninger til din industri

62 Spørgsmål