Objective
The project carried out at the SA CAMP-BENCKISER Group plant basically consists of a new system for the atomization of solid detergent with self-production of electricity. The aims of this are as follows :
- To optimize the energy consumption and costs of the detergent atomization process.
- To assure a supply of electricity to key points in the factory in case of a mains power cut.
- To improve environmental conditions.
- To self-produce electricity.
- To optimise the production and quality of th atomized detergent through a greater degree of automation of the atomization plant.
- To gather energy information to improve energy management and optimisation.
- To reduce the lulls in production.
The results obtained up to now have been totally satsifactory, both in terms of energy saving and financial saving. Furthermore, there are well-founded hopes that the present ratios will improve and, therefore, the project has been a total success.
This fact means that the ability to reapply the project is high.
Although initially it was not known with any real degree of certainty how this project would affect the use of hot gases from the turbine to the product, now it has been shown that it is perfectly valid to use exhaust gases from turbines to atomize detergents. This type of installation can allow the energy costs of other industries in the sector to be reduced, as well as any industry which involves atomization processes, so long as the operating hours of the installation and the energy process allow such an installation to be profitable.
A certain amount of filtered air is compressed and passes through a combustion chamber where it is used as a comburent of natural gas. Its combustion gives produces hot gases which are sent to a turbine where they are expanded, obtaining thus electricity through the generator which is activated by the said turbine.
Operation modes:
1. DETERGENT DRYING.
The gases from the turbine are mixed with the gases from the air-vane burner. The "plenum" foreseen in the connection of both conduits ensures enough turbulence to homogenise the temperature of the mixture.
Flow and temperature adjustment of the mixture of gases is carried out by acting on the flow and temperature of the air-vane gases. The flow is adjusted to a set value depending on the product that has to be dried through the butterfly valve in the suction of the dilution air ventilator, whilst the temperature of is adjusted through the temperature control link which acts on the combustion system in the air-vane and the turbine gas flow depending on the temperature of the mixture of incoming gases from Tower IV.
The whole of the new drying process, as well as the control parameters of the atomization process have been automated through a centralised control system run which runs the whole process through PLC, operating from a remote screen.
2. STEAM GENERATION
During the periods when Tower IV is stopped, and in order to improve the performance of the system, the exhaust gases from the turbine are used to generate steam in a recovery boiler for the factories own use.
If the energy from the exhaust gases of the turbine is greater than the energy required for the steam production consumed by the factory, a proportion of the gases will be diverted into the atmosphere depending on the demand for steam. This by-pass is carried out by a valve on the exit of the turbine. The valve regulate the flow of gases sent to the recovery boiler depending on the thermal demand.
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Coordinator
08400 GRANOLLERS
Spain
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.