Objective
The project pretends two objectives :
- Reducing electrical energy costs via substitution of the electric energy supply from national distributor (Union Fenosa SA) with selfgeneration in a very efficient cogeneration plant (thermal balance > 65%).
- Cleaning 16.9 m3/hour of waste water in an evaporation plant making use of residual thermal energy (exhaust air, refrigerating water) from the motor.
The design figure of approx. 6.500 kW covers maximum peak electric energy demand (average is about 3.500 kW) and enables TRADEMA to sell about 3.000 kW to the EE supplier Union Fenosa.
Based on actual parameters (fuel-oil and bark prices, 270 days/year in operation, etc) and estimated 965 MPtas investment, a total saving of 241 M Ptas/year in cost of energy will be obtained. This means a 4 years payback and 15% IRP after taxes.
The project suffered several delays. In October 1994, IDAE, TAFISA and TRADEMA constituted a Consortium of Economic Interest, by way of which IDAE would bring to the Consortium more than 800 million PTA in credits or through partners.
According to the last available news from the project, the mechanical completion of the evaporator (the engine is in operation since March 1995) should be terminated at the end of 1995; the start-up should be finished in May 1996, and the follow-up and tests of the global project will be done in two following months of 1996. Primary energy saved in power generation : 5,120 TOE.
The positive environmental impact is twofold :
- Due to energy saving
- Due to the elimination of a liquid waste stream.
GENERAL
The cogeneration project applied to the plant can optimize balance between both electric and thermal energies and reduce prices of kWh.
Electrical average energy consumption is around 3500 kWh and average price paid is around 10,5 ptas/kWh. The cogeneration plant would produce around 6500 kWh. That means 3500 kWh selfconsumpted in the factory and 3000 kWh sold to the Electric Company. Fuel-oil cost per produced kWh is less than 4 Ptas/kWh. Therefore there are enough margin to paid investment and to generate electrical energy costs saving.
The optimal energy balance in a cogeneration plant is obtained by the right and most efficient use of the waste energy that means exhaust gases and refrigerating water.
EXHAUST GASES
The total exhaust gases volume at 320 deg. C will inlet into a heat recovery exchanger. This exchanger will produce total steam of 3100 Kg/hr at 10 bars. This steam will be applicated for the evaporation plant (750 Kg/hr at 5 bars) and for the board process (2350 Kg/hr at 10 bars approx.).
REFRIGERATION WATER CIRCUITS
There are two outcoming refrigerating circuits from the Motorgenerator.
The low temperature circuit (216 m3/hour, around 46 deg. C) is not suitable to be used in the industrial process. The high temperature circuit (216 m3/hour, around 91 deg. C) it can be applied in :
- Warming up 3100 Kg/hr incoming water for producing steam in the heat recovery exchanger (from 15 deg. C to 90 deg. C, 232 th/hr)
- Recovering 4300 Kg/hr of flash vapour (2.272 th/hr) under vacuum in a flash vessel.
SUMMARY
Mixing all these concepts we arrive to a system very efficient. The thermal efficiency of the Cogeneration plant (Fuel-oil thermias apported comparing with net thermias used in the process) will be higher than 70%.
The primary energy saving will be more than 44%.
Primary energy saving expressed in TOE (fuel-oil equivalent tons/year) will be around 5.120 TOE/year.
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Coordinator
15300 INFESTA BETANZOS (LA CORUNA)
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.