Objective
With regard to the system for purifying the gases loaded with organic matter resulting from thermic after-burning, which involves investments, operating costs and uneconomical maintenance procedures, to prove that it is possible to purify the output air flow loaded with harmful substances originating in the offset web machines while at the same time minimizing operating costs (by means of automatic function) and reducing the consumption of prime energy (by integrating the processes in a power cold-heat coupling system).L%
CONSTRUCTION PHASE
The foundations were laid in December 92 and then, in January 93, the construction of the production bay was begun. By mid-February 93, the gas turbines had arrived on site and the HT/AKM machines had been delivered; it was then that the GRUNDNER company then began to assemble the hot air pipes. Towards the end of that same month, the cooling towers has also been supplied.
Once the large sets had been set accurately into place, it was possible to complete the assembly of the hot air pipes; this occured during the last fortnight of March 93. The assembly of the cold water and refrigeration pipes was carried out at the same time, with the Spanish INGEFLUID company being in charge of this task.
The generating sets were supplied by AEG whereas the wiring and electric installation on site were carried out by the Spanish SURIS company. Both AEG and INGEFLUID, as well as SURIS, collaborated closely with the MICHELBACH Messund Regeltechnik company, so there was good harmony right from the start.
Kraftanlagen Heidelberg took charge of the works inspection duties and, moreover, the PRINTER ESPANA company placed its own works engineer at the project's disposal. The printer company, at its own responsibility, took charge of coordinating the project in such a way that it was always possible to count on the presence of the pertinent technical staff on site. This procedure contributed to avoiding essential inactive periods in the project's development.
At the end of April 93 it was thus possible to start up the turbines' cold processes and then to start up the heat ones; once these were under way, tests on the function of the HT-AKM with the cold water supply could be made. The HT-AKM were started up with no problems. However, laying out the new design of the cold water supply took several weeks as adapting the new cold water system to the existent circuit required detailed modification and regulation tasks. The same may be said of the assembly of thecooling water pipes.
In view of the success achieved in starting up the turbines, including connecting the electricity production to the public network as well as the correct function of the cold water system, we were able to commence producing electricity and cold by the end of June 93.
PERFECTING PHASE
The joint production of electricity and cold, regulated in a totally automatic manner, started in July 93. The production results are very good. Both the production of electricity and of cold water for the cooling processes and air conditioning purposes, as well as for heating, is on the whole being carried out in a fully automatic way without any alterations which, to date, are worthy of mention.
Once this first production was under way, and as an immanent part of the process, the assembly of the pipes for burning the harmful substances from the rotary machine dryers began. This second phase of the project as planned took place towards the end of October 93.
GENERAL
In view of the increase in web-production in the offset printing section, it was necesary to increase also the energy supply facilities. As a consequence of the excessive ageing of the existent system, the company decided to redesign this sector globally and, in addition to the energy saving systems, special consideration was given to the environment protection aspects.
The cold water supply system as a whole (for cooling procedures in the processes and air conditioning aspects) had to be perfected as this had been installed redundantly and therefore was using up too much energy. At the same time, possibilities were sought to devise new ways of integrating the system for eliminating harmful substances into this energy programme.
BASIC TECHNICAL CONDITIONS
Offset web machines are the main energy consumers in an offset printing plant. Apart from the electric driving power, they require above all gas for drying the paper web (approx. 600 kW) and cold for cooling the webs (approximately 300 kW). The paper web drying process is carried out in large ovens (up to 12 or 15 metres long) placed behind the printing process. From the gas ovens, which dry by air-flow processes, an air enriched with mineral substances and solvents (1.5 - 3.0 mg/m3) either flows from a chimney on the roof or is burnt in accordance with general after-burning procedures.
Other consumers of cold are the air conditioning installations for the production plants, the facilities used or stages prior to the printing itself, the data processing device rooms and the offices. Cold is also used in the production of compressed air.
THE PROGRAMME
So that the programme described here below could continue to evolve on a long term basis, it was essential for the provisions to include in advance the developments in environmental policy; in this case, therefore, the programme was to include not only the rational use of energy but also the elimination of the output of harmful substances, or the integration of both items intelligently from an economic and technical approach.
The energy should be produced rationally in a power-cold-heat coupling system; at the same time, the emission of harmful substances should be avoided by means of integrating their elimination in this same process (burning in gas turbines in the course of energy production) without having to add any of the usual after-burning installations.
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Coordinator
08620 SANT VINCENC DELS HORTS (BARC)
Spain
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