Objective
A Superheater and a vacuum Turbine Generator will receive 40% of the back pressure steam of the Turbogenerator of the ETMA Power Station. The system will cost 380 million drs., (2,30 million ECU), and will produce 35% more Electric Power (with a 5% increase in fuel) plus low temperature and pressure steam, to heat water and replace steam in the following applications :
a. Air Conditioning of process areas, and
b. Heating to 55 deg. C the spinning baths.
The combination of known (Vac Turbine) to innovative Technology (warm water for Air-Conditioning) will result to:
a. Increase of the boiler efficiency;
b. Cogeneration of additional Electric Energy at 80 gr of fuel consumed
per kWh charge;
c. Payback period of 3-4 years, considering the fuel savings and
the Electric Energy charge, which is 3-4 times higher, and,
d. Saving of 2200 TOE/year compared to the Public Power Company production.
The ETMA Power Station produces 50 tons of steam at 62 BAR/460 deg. C, passed through a back pressure Turbogenerator to give 132 kWh/ton and 3,4 BAR Steam.
According to the proposed new scheme, 40% of the back pressure steam will pass through a Superheater and a Vacuum Turbogenerator, to produce additional Power Energy and low Pressure/Temperature "Condenser" Steam, still capable for heating water to be used in low temperature demanding applications, namely:
a. Air Conditioning of process areas, through 17 Humidifying Units (using today 32% of the total team), and,
b. Heating up to 55 deg. C, of the spinning baths (8% of actual steam). The Concept of the system is to maximize benefits from the cogenerated Energy produced at 1/3 of the cost charged by the Public Power Corporation.
The Innovation of the system is to use warm water to heat 2 million m3 of air in 17 Heating Humidifying Units, and Spraying warm water in spray towers, to obtain the required Relative Hunidity for conditioning this air, supplied to the process areas.
The economic impacts of the new scheme on the costs of ETMA will be:
a. The Superheater will increase the boiler efficiency from 92% to 93,5-94%, saving 450 TOE/year and improving the steam quality to the Vacuum Turbine;
b. Additional Electric Energy is produced at 117,5 kWh/ton of primer steam (which corresponds to 75% of the Vac Turbine feed) and 42,8 kWh/ton of extracted steam (25% of the Vac Turbine feed); c. Thus 30-35% more Electric Power is cogenerated (44 million kWh/year versus 32 million kWh, by increasing the fuel consumption by only 5%. Additional Energy is produced essentially at a fuel consumption of 80 gr/kWh. Fuel Energy converted to Electric Power will increase from 16,5% to 22% and overall Electric Power cogenerated, from 1,65 to 2,2 kWh/kg fuel;
d. Additional Electric Energy will cost, in fuel and direct expenses, 2,16 drs/kWh (0.0131 ECU/kWh) versus 2,45 drs/kWh (0.0148 ECU/kWh) of the actual operation. The total savings to the average Electric Energy cost of 8,9 drs/kWh (0.054 ECU/kWh) charged by the Public Power Corporation (3-4 times higher), is 83.000.00 drs (475.000 ECU/year) and the resulting payback period of the project is 3-4 years.
e. Major operations of the factory become essentially independent to External Power Supply, peak consumption charges are avoided and ETMA will benefit from labor cost and low quality products occuring after Power Failures;
f. Finally, 2200 TOE/year are saved, when comparing the efficiency of the Cogenerating ETMA Unit to the efficiency of 35% of the Public Power Company.
Seasonal but also the hourly fluctuations in the demand of heating Energy for the Humidifying Units, require specific attention, monitoring and control of the whole operation, in order to obtain the optimum conditions and get the maximum benefit, as close as possible to the theoritically calculated results.
Topic(s)
Call for proposal
Data not availableFunding Scheme
DEM - Demonstration contractsCoordinator
11855 Athens
Greece