SATURATED STEAM-TURBINE WITH ELECTRICITY GENERATION WITHOUT CO2 EMISSIONS AND NO ADDITIONAL ENERGY CONSUMPTION

Objective

- Reduction of equivalent CO2 emissions by about 9% for TDK, means about 3580 t/y.
- Production of electrical energy by using waste heat, about 5324040 KW/Y, means about 14% of present yearly consumption.
- Production of electricity as a function of energy recycling within a closed circuit.
- Increased electricity yeld of turbine/generator unit by improving nozzle- and blade-design.
- No additional energy consumption. No additional primary energy.
- Replication potential for other users of EGI systems.
- Saving of about 7856000 LUF/y on energy expenses.

Project estimation : 643 KW per hour

Average electricity generation :
October : 662 KW/H
November : 653 KW/H
December : 657 KW/H
January : 595 KW/H
February : 662 KW/H
March : 641 KW/H
April : 620 KW/H
AVERAGE : 641 KW/H
TDK Recording Media Europe SA runs a fully integrated factory for the production of Audio and Video-tapes in Bascharage, Grand-Duchy of Luxembourg. Fully integrated means that form the base film and the painting materials (mixed with solvents), all steps of the production of the final product are covered within the same site.
For environment reasons TDK is operating two exhaust gas incineration lines, combined with waste heat boilers for the generation of saturated steam. The so-called EGIs (Exhaust Gas Incinerators) are used to incinerate the solvents evaporating during the paint production, the coating and the tape drying process.
One incineration line covers the Audio production and the other one covers the Video production. Both have the same capacity : - Incinerated air-volume, loaded with evaporated solvents : 27000 Nm³/h each
- Natural gas consumption to support combustion : about 200 Nm³/h each
- Steam capacity : 8 t/h steam of 9 bar abs.
The incinerators were installed as environmental protection units. By keeping a constant incineration temperature of 780°C, emissions are kept well below the strict rates imposed by the Luxembourg authorities and the operating permission. During the last 3 to 3 1/2 years TDK has achieved to reduce energy consumption of production process. The project will implement the following equipments :
- re-ajustment of design-capacities of both waste-heat boilers to 2*4 t/h, 9 bar abs; - cutting off heat exchangers for building- heating from steam supply. Instead of this, heating water will be warmed up by two newly to install economizers located in the hot air exhausts of the two EGIs; - installation of saturated steam-turbine for a steam quantity of 7.2 t/h, 9 bar abs and a power generator for the production of three-phase current with a tension of 400 V and a capacity of 750 KWe; - supply of the so-produced electricity into the low tension network of a transformer with a capacity of 1600 KVA. Usage of the electricity produced in the coating and drying process; - installation of a vacuum condenser with an outlet pressure of 0.08 bar and an outlet steam temperature of 42°C; - installation of an atmosphere cooling tower for the cooling of the condenser mentioned; - installation of a pre-heater into the pre-flow line of heating for the warming-up of the turbine condensate to about 90°C before feeding into the condensate collector in the boiler-house; - tie-in all needed pipelines for cooling-water, steam, condensate, heating, etc.; - construction of the foundations for turbine, vacuum-condenser, generator and cooling tower; - electrical wiring for power supply to transformers; drives; etc, needed in the equipment (pumps, controllers, counters, etc.)

Fields of science

Programme(s)

FP4-NNE-THERMIE C - Specific programme for research and technological development, including demonstration in the field of non-nuclear energy, 1994-1998

Topic(s)

6.2 - INDUSTRY

Call for proposal

Data not available

Funding Scheme

DEM - Demonstration contracts

Coordinator

TDK RECORDING MEDIA EUROPE SA

EU contribution

No data

Address

ZI BOMMELSCHEUER
4902 BASCHARAGE
Luxembourg

Total cost