Presentation on theme: "Improving power efficiency—why not now?"— Presentation transcript:
1 Improving power efficiency—why not now? Tim Batton with Oxistop LLC, USAImproving power efficiency—why not now?
2 Improving Power Efficiency—Why Not Now? welcome and thank youEnergy Efficiency: Improving Power EfficiencyImproving Power Efficiency—Why Not Now?Oxistop LLCYoungstown State UniversitySustainable Energy ForumJune 8, 2010
3 presentation objectives Defining the opportunityIntroduction of the existing technologiesBenefits of the existing technologiesRecognizing obstaclesOvercoming obstacles
4 energy efficiency and conservation Economic RealitiesCurrent economic realities have forcedthe Power Utility Industry and America's Heavy Industriesto use what was considered by them to be discretionarydollars as a means of maintaining basic operations,leaving little money or incentive for investing in new technologies for efficient power generation development.
5 Improving power efficiency—why not now? “It's hard to remember now.But before Congress got all bogged down with healthcare reformlast summer, the House had passed a major piece of energy and climate legislation that would have capped greenhouse gas emissions and put billions into renewable energy and new technologies...”K.G. U.S. News & World Report, Summer 2010
6 Magnetic Field Technologies energy efficiency and conservationCeramic Coatings AndMagnetic Field TechnologiesTechnologies exist today that are proven solutionsin other industries for problems associated with energy efficiency and energy conservation issues and haveexisted for many years.
7 Why Are The Technologies Not Being Used In The Power Utility Industry? energy efficiency and conservationWhy Are The Technologies Not Being UsedIn The Power Utility Industry?No real economic incentive to change current practicesNew to the Power Utility Industry, where they are considered experimentalNot fully validated and tested by the Power Utility Industry
8 energy efficiency and conservation Ceramic Coatings And Magnetic FieldsWhat Are Some Of These Technologies?High emissivity Ceramic coatings for energy enhancementLow emissivity Ceramic coatings for energy conservationMagnetic Field Units (MFU), conservation of finite natural resources for fuel and water treatment technologies
9 high emissivity ceramic coatings Ceramic boiler tube coatings improvepower generation and reliability of the boilerwhile reducing emissions.improving fuel efficiencies in various industriesreducing slag and residue buildupresisting corrosion and erosionpreventing oxidation of boiler tubesALL CRITICAL TO EFFICIENCY AND AVAILABILITY OF POWER GENERATION EQUIPMENT
10 Oak Ridge National Laboratory U. S. Department of Energy slag challenges & coating solutionsSlag buildup creates many problems, including loss in boiler efficiency, potentially damage to the unit and danger to personnel from falling slag.Procera™ CoatingBase metalOak Ridge National Laboratory U. S. Department of EnergySlag buildup on uncoated tube wallSlag that has shedoff the ceramic coated tube wallMagnification of ceramic coating bond with carbon steel substrate
11 Challenges: Oxidizing High Sulfur Conditions corrosion challenges & coating solutionsChallenges: Oxidizing High Sulfur Conditionsfurnace gas (pyrite)tube metaloxideslagsulfide corrosionsulfides
12 Solution: Ceramic Coatings—Protective Layer corrosion challenges & coating solutionsSolution: Ceramic Coatings—Protective Layertube metalCeramic Coatingslagfurnace gas (pyrite)Procera™ MC19-GRP—Protective LayerCeramic Coatingprovide a “protective layer,” through complete chemical and mechanicalbonding to thetube’s surface
13 AEP ceramic coating case study (how does this work)American Electric PowerPicway Power Plant( )
14 Trial area around burners to stop slag buildup AEP ceramic coating case studyFirst Installation.Trial area around burners to stop slag buildupBefore coating install, burner with upper eyebrowTrial burner grit blastsurface preparationTrial burners with ceramic coating applied
15 Technology is verified in the field AEP ceramic coating case studyTechnology is verified in the fieldBefore coating install, uncoated with eyebrowCoated burner wall, note excellent flame profileSlag shedding off burner wall coated withceramic coating
16 NRG ceramic coating case study Huntley’s expectationsof the coatings•coating will lessen the thermal shock and damage to tubingoverall heat absorption in the furnace will improvecost of application is below that of other corrosion coating options•NRG Energy IncHuntley Power Plant( )•
17 payback for the cost…24 DAYS NRG ceramic coating case studypayback for the cost…24 DAYSResults•lower furnace exit gas temperatures (FEGT) as a result of greater absorptionlower fuel (coal) usage eliminating over firing to make steaming ratemaximum megawatt output is increased to full load of 198 Megawatts, with slightly less coal burned•…Payback for the cost of the Procera™ coating application was 24 days. Continual monitoring verifies heat transfer data indicating power output increase remaining constant after more than six months on-line as a result of the Procera™ coating application.•
18 AECI ceramic coating case study New Madrid's 600-megawatt units can each burn about 7,000 tons of coal per day, some five million tons per year. Low-sulfur coal travels 1,235 miles from Wyoming to New Madrid by rail, traversing four states. A coal train is a set of 115 cars, each holding about 121 tons of coal. A unit train's coal shipment totals some 13,900 tons.Plant statisticsUnit Brown-Boveri turbineNet capacity is 600 megawatts.Unit Brown-Boveri turbineNet capacity is 600 megawattsAssociated ElectricCooperative IncNew Madrid Power Plant(April, 2008)
19 NEW MADRID POWER PLANT CHALLENGES: ash fowling before coatingsNEW MADRID POWER PLANT CHALLENGES:ash fowling control of inlet and outlets of secondary superheater (SSH)slag bridging across front of SSHimproving fuel efficiencies and heat absorption by reducing slag
20 Uncoated next to coated, after 6 months online, un-cleaned
21 Economizer Outlet Flue Gas Temperature New Madrid’s coating observationsEconomizer Outlet Flue Gas Temperature•no bridging across front of SSHSSH fouling rate approximately half of historic ratecoating visible In some areas and overall condition appears very goodhigher heat absorption rate•NM1 Secondary SuperheaterNo Bridging Across Front of SSHLight PlatinizationOxistop Coating Visible In Some AreasOverall condition appears very good.NM1 Pendant ReheaterModerate PlatinizationModerate BridgingApproximately 6 foot band across middle of PRH is fouled.PRH is clean above and below this band.A few spots of Oxistop found on leading edge of PRH.Overall condition appears good.•U1 Current Run (Oxistop, 2008)U1 Summer, 2007 (Control)U1 Average Summer, 2004 – Winter, 2006–2007•
22 coating application areas (a comprehensive approach)Boiler BankEconomizerSuperheaterAir HeaterCombustion ChamberDust CollectorHot Cyclone CollectorID FanHigh emissivity coatings for energy enhancement (Production Side)Low emissivity coatings for energy conservation (Conservation Side)
23 low emissivity ceramic coatings Ceramic thermal insulating coatings forenergy conservation that reduce energy cost andprovide emission control.excellent thermal insulation at low thicknesseseliminates Corrosion Under Insulation (CUI)easy application to irregular surfacesexcellent personnel protectionconventional insulation
24 low emissivity ceramic coatings What is the difference between conventional insulation and Thermal Insulation Coatings (TIC).conventional insulationthermal insulation coatingsCUIDifficult RepairsMaintenanceWear/VibrationNo Inspect AbilityLimited ProtectionNo More CUIEasy Repairs/Touch UpsNo Regular MaintenanceVirtually No WearTotal Inspect AbilityConstant Substrate ProtectionJob was expedited by Hurricanes Katrina & Rita
25 thermal insulation coating (TIC) ceramic coating case study I Diffuser•Sugar mill diffuser was not cost effective to conventionally insulateCoating was selected due to its rapid application as well as total service abilityPost application all of its sugar mill process was well within the design parameters and allowed the facility to save tremendous dollars on energy•Substrate: Diffuser (sugar mill)Problem: CUI, Personnel Protection,Heat RetentionReason: Needed to keep diffuser at steady temp and protectpersonnel from burnsStarting Temp = 190°F (87°C)Post app. Temp = 110°F (43°C)DFT = 60 mils•
26 thermal insulation coating (TIC) ceramic coating case study II Shell Heat Exchanger•Unit had a process temperature requirements starting at 200F and tapering to 100 F. The coating allowed the facility to save costs of total insulation as the application could be tailor-sprayed to temperature requirements.Use of DTI brought the goal of Personnel Protection well with their limits and eliminated CUI.Substrate: Shell Heat ExchangerProblem: CUI, Personnel Protection,Reason: Ease of maintenance, personnel protectionStarting Temp = 200°F (93°C)Post app. Temp = 110°F (43°C)DFT = mils ( mm)•
27 How Do The Coatings Work? coatings for energy conservation(commercial applications)How Do The Coatings Work?
28 water treatment Magnetic Field Units (MFU), conservation of finite natural resources for fuel and watertreatment technologies.No energy required to operateHas no parts subject to wear and nomoving parts (No maintenance)Greatly reducing of chemical expenses associated with water treatmentMagnet system is a permanent solution to water treatment issues, giving immediate benefitLife and effectiveness of the system with match the operating equipment
29 and Boiler Efficiencies water treatmentCooling Water Systemsand Boiler EfficienciesMagnetic Field Units for water replace the cost of chemicals and maintenance cleanings by applying a safe, permanent, cathodic protection voltage to cooling process liquids.The MFU aggressively removes hard scale, deposits, and bio-fouling that can reduce or eliminate waterside related maintenance outages.
30 and Boiler Efficiencies water treatmentCooling Water Systemsand Boiler EfficienciesCooling towers and condensers can create a back pressure within the turbine if the system’s efficiency is compromised by calcium carbonate build up and organic matter accumulation.The traditional way to treat this occurrence is to treat the system with chemicals to deal with the various issues—a costly balancing act never 100% effective, and scheduled cleanings are required and a certain amount of back-pressure is tolerated.
31 9% Increase In Power Output Reported Birchwood 9% Case Study9% Increase In Power Output ReportedWith HYDROLATOR™9% increase, to reach designed capacity (output reached 256 MW)20 MW additional production (Historically, this plant's peak output never exceeded 236 MW)No condenser cleaning was required after increased power output and installation—$300,000/yr savings in chemical treatment expenses$7 million/yr profit as a result of increased power output and HYDROLATOR’s permanent cleaningHYDROLATOR equipment has been utilized since 2000 with consistent performance results
32 for fuel: MAXSYS FUEL SYSTEMS fuel conservationMFU for conservationfor fuel: MAXSYS FUEL SYSTEMSIn-line magnetic fuel treatment system (minimum 5% fuel savings assured)Pre-treat gas and oil prior to combustion to enhance combustion efficiency while lowering emissionsRetrofit system - no power or maintenance requiredNo interference to the process and combustion plantDoes not affect burning equipment warrantyCompatible with all burners across a range of industries
33 YES IT CAN! Can Power Efficiency Be Improved Today? pushing and pullingstrategies effect energy flowCan Power EfficiencyBe Improved Today?YES IT CAN!BY “PUSHING” WITH CERAMIC COATINGS AND“PULLING” WITH MAGNETIC FIELD TECHNOLOGIESTO CREATE NEW ENERGY FLOW DYNAMICSWHAT DOES THIS MEAN…
34 pushing and pulling energy flow Push And Pull Strategies For More Efficient Power Generation And Increased Revenue Income
35 Inherent problems are that vested interest recognizing obstaclesInherent problems are that vested interestgroups are against new technologies for energy efficiency and conservation because:the “why fix what is not broke”owners and operators are “set in their ways” (stay the course) or feel that their job security is at risk.in many cases, fuel costs are passed-on to the end consumer.boiler manufacturers’ answer is to “simply build a bigger box [boiler].”owners have vested interests in traditional technologies; such as chemicals; different boiler and burner designs; or other tube coating technologies such as weld overlay and thermal (metal) spray.
36 Additional Funding (Grants) And Real Incentives For: overcoming obstaclesAdditional Funding (Grants)And Real Incentives For:$ For Funding – RESEARCH AND VALIDATION, such as education institutions and testing and research facilities such as Babcock & Wilcox Company Research Center (BWRC) in Barberton, Ohio.$ For Funding – FIELD TRIALS with “End Users”—Heavy Industry and Power Generation (Companies that would benefit by use of these Technologies)$ To Provide Funding – For companies that specialize in promoting new technologies that are dedicated to energy efficiency and conservation.
37 Improving power efficiency— why not now! Today’s use of these technologies can be thebridge to our future evolution in efficient productionand conversation of our energy resources.Tim Batton, PresidentOxistop LLC • Salem Energy Solutions • Sáetech LLCPhone: • Cell:1413 Quaker Circle, Salem Industrial Park • Salem, Ohio •