Objective
Energy conservation and better utilization of energy during generation of heat gas for a drying process operation.
Energy extracting during generation of saturated steam for a crystalization process operation.
Two existing rotary tubular kilns shall be heated by the exhaust gases of two gas-driven motor generator sets to be installed, instead of the current natural gas burners.
One generator set will additionally drive a vapour compressor unit, that converts the polluted, low-temperature reaction steam from a chemical process (crystallization system) into naturated steam appropriate for the heating. The energy for preheating and vaporizing the feedwater will be conserved through this vapour compressor.
The steam will be purified before compression.
Expected energy saving of the production is 7800 MWH/yr (natural gas) = 685 t raw oil (at 6000 operating hours per year)
Annual savings are approx. 543.000 DM.
Two rotary tubular kilns shall no longer be heated by simple firing of natural gas. Two motors will be installed and their exhaust gases used to heat the rotary tubes. Each motor drives a generator, so that power will be cogenerated along with the heating gases (motor exhaust gases). One motor generator set additionally a vapour compressor, that rises the temperature of the cold saturated steam (70 deg. C) from a third facility (crystallization system) to a higher level (100 deg. C); this saturated steam, that is not being used, can then be utilized. The heating team has been generated in a boiler using fresh feedwater up to now. The energy for preheating and vaporizing of the feedwater will be saved by use of a vapour compressor unit.
The saturated steam (vapour steam) to be compressed aggressive impurities. A purification process had been developed to remove the pollutants.
One rotary tube has a heating gas demand of approx. 1.700 Nm3/h; herefore a motor with the corresponding exhaust gas output was selected. The capacity of this motor at tuhe shaft is 350 kW. The generator driven with this motor generates an output of 325 kW.
A motor with the same capacity will be installed for the other rotary tube. The motor exhaust gases will be brought to the volume and temperature required by rotary tube through additional burner firing natural gas.
The vapour compressor generates 0,322 kg/s saturated steam (110 deg. C) to heat a crystallization system. The steam to be compressed (vapour steam) is released of the crystallization process (0,28 kg/s, 70 deg. C, saturated steam). Since the vapour steam is heated above 110 deg. C by the compressor (130 kW), the desired final temperature (110 deg. C) must be obtained through water injection.
The relevant vapour steam has not been used up until now, due to its low temperature level and aggressivwe pollutant content.
The pollutants consists of entrained, aggressive crystal suspensions form the reaction products, that tendto conglutinate (droplet entrainment).
In the projected design, the exhaust will be cleaned. The purifier unit does not modify the condition and volume of the vapour steam, since the purification water is pumped through a circuit and assumes the temperature of the steam. Losses only occur during system run-up.
Topic(s)
Call for proposal
Data not availableFunding Scheme
DEM - Demonstration contractsCoordinator
6802 Ladenburg - Neckar
Germany