Presentation on theme: "Improving power efficiencywhy not now?. Energy Efficiency: Improving Power Efficiency Improving Power EfficiencyWhy Not Now? Oxistop LLC Youngstown State."— Presentation transcript:
Improving power efficiencywhy not now?
Energy Efficiency: Improving Power Efficiency Improving Power EfficiencyWhy Not Now? Oxistop LLC Youngstown State University Sustainable Energy Forum June 8, 2010 welcome and thank you
Defining the opportunity Introduction of the existing technologies Benefits of the existing technologies Recognizing obstacles Overcoming obstacles presentation objectives
Current economic realities have forced the Power Utility Industry and America's Heavy Industries to use what was considered by them to be discretionary dollars as a means of maintaining basic operations, leaving little money or incentive for investing in new technologies for efficient power generation development. energy efficiency and conservation Economic Realities
It's hard to remember now. But before Congress got all bogged down with healthcare reform last 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 Improving power efficiencywhy not now?
Technologies exist today that are proven solutions in other industries for problems associated with energy efficiency and energy conservation issues and have existed for many years. energy efficiency and conservation Ceramic Coatings And Magnetic Field Technologies Ceramic Coatings And Magnetic Field Technologies
No real economic incentive to change current practices New to the Power Utility Industry, where they are considered experimental Not fully validated and tested by the Power Utility Industry energy efficiency and conservation Why Are The Technologies Not Being Used In The Power Utility Industry? Why Are The Technologies Not Being Used In The Power Utility Industry?
High emissivity Ceramic coatings for energy enhancement Low emissivity Ceramic coatings for energy conservation Magnetic Field Units (MFU), conservation of finite natural resources for fuel and water treatment technologies energy efficiency and conservation Ceramic Coatings And Magnetic Fields What Are Some Of These Technologies? Ceramic Coatings And Magnetic Fields What Are Some Of These Technologies?
high emissivity ceramic coatings improving fuel efficiencies in various industries reducing slag and residue buildup resisting corrosion and erosion preventing oxidation of boiler tubes Ceramic boiler tube coatings improve power generation and reliability of the boiler while reducing emissions. Ceramic boiler tube coatings improve power generation and reliability of the boiler while reducing emissions. ALL CRITICAL TO EFFICIENCY AND AVAILABILITY OF POWER GENERATION EQUIPMENT
Base metal Procera Coating Slag buildup creates many problems, including loss in boiler efficiency, potentially damage to the unit and danger to personnel from falling slag. slag challenges & coating solutions Slag buildup on uncoated tube wall Slag that has shed off the ceramic coated tube wall Magnification of ceramic coating bond with carbon steel substrate Oak Ridge National Laboratory U. S. Department of Energy
corrosion challenges & coating solutions furnace gas (pyrite)tube metal oxide slag sulfide corrosion sulfides Challenges: Oxidizing High Sulfur Conditions Challenges: Oxidizing High Sulfur Conditions
Solution: Ceramic CoatingsProtective Layer Solution: Ceramic CoatingsProtective Layer tube metal Ceramic Coating slagfurnace gas (pyrite) Procera MC19-GRPProtective Layer Ceramic Coating provide a protective layer, through complete chemical and mechanical bonding to the tubes surface corrosion challenges & coating solutions
AEP ceramic coating case study (how does this work) American Electric Power Picway Power Plant ( )
AEP ceramic coating case study Before coating install, burner with upper eyebrow Trial burner grit blast surface preparation Trial burners with ceramic coating applied First Installation. Trial area around burners to stop slag buildup First Installation. Trial area around burners to stop slag buildup
AEP ceramic coating case study Technology is verified in the field Before coating install, uncoated with eyebrow Coated burner wall, note excellent flame profile Slag shedding off burner wall coated with ceramic coating
NRG ceramic coating case study Huntleys expectations of the coatings Huntleys expectations of the coatings NRG Energy Inc Huntley Power Plant ( ) coating will lessen the thermal shock and damage to tubing overall heat absorption in the furnace will improve cost of application is below that of other corrosion coating options
NRG ceramic coating case study payback for the cost…24 DAYS lower furnace exit gas temperatures (FEGT) as a result of greater absorption lower fuel (coal) usage eliminating over firing to make steaming rate maximum megawatt output is increased to full load of 198 Megawatts, with slightly less coal burned Results
Associated Electric Cooperative Inc New Madrid Power Plant (April, 2008) AECI ceramic coating case study
ash fowling before coatings NEW MADRID POWER PLANT CHALLENGES: ash fowling control of inlet and outlets of secondary superheater (SSH) slag bridging across front of SSH improving fuel efficiencies and heat absorption by reducing slag
Uncoated next to coated, after 6 months online, un-cleaned
New Madrids coating observations no bridging across front of SSH SSH fouling rate approximately half of historic rate coating visible In some areas and overall condition appears very good higher heat absorption rate Economizer Outlet Flue Gas Temperature U1 Current Run (Oxistop, 2008) U1 Summer, 2007 (Control) U1 Average Summer, 2004 – Winter, 2006– 2007
1.Boiler Bank 2.Superheater 3.Combustion Chamber 4.Hot Cyclone Collector 5.Economizer 6.Air Heater 7.Dust Collector 8.ID Fan coating application areas (a comprehensive approach) High emissivity coatings for energy enhancement (Production Side) Low emissivity coatings for energy conservation (Conservation Side)
low emissivity ceramic coatings excellent thermal insulation at low thicknesses eliminates Corrosion Under Insulation (CUI) easy application to irregular surfaces excellent personnel protection Ceramic thermal insulating coatings for energy conservation that reduce energy cost and provide emission control. Ceramic thermal insulating coatings for energy conservation that reduce energy cost and provide emission control. conventional insulation
low emissivity ceramic coatings What is the difference between conventional insulation and Thermal Insulation Coatings (TIC). CUI Difficult Repairs Maintenance Wear/Vibration No Inspect Ability Limited Protection conventional insulation thermal insulation coatings No More CUI Easy Repairs/Touch Ups No Regular Maintenance Virtually No Wear Total Inspect Ability Constant Substrate Protection Job was expedited by Hurricanes Katrina & Rita
thermal insulation coating (TIC) ceramic coating case study I Diffuser Substrate: Diffuser (sugar mill) Problem: CUI, Personnel Protection, Heat Retention Reason: Needed to keep diffuser at steady temp and protect personnel from burns Starting Temp = 190°F (87°C) Post app. Temp = 110°F (43°C) DFT = 60 mils Sugar mill diffuser was not cost effective to conventionally insulate Coating was selected due to its rapid application as well as total service ability Post application all of its sugar mill process was well within the design parameters and allowed the facility to save tremendous dollars on energy
Shell Heat Exchanger Substrate: Shell Heat Exchanger Problem: CUI, Personnel Protection, Reason: Ease of maintenance, personnel protection Starting Temp = 200°F (93°C) Post app. Temp = 110°F (43°C) DFT = mils ( mm) 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. thermal insulation coating (TIC) ceramic coating case study II
coatings for energy conservation (commercial applications) How Do The Coatings Work?
water treatment No energy required to operate Has no parts subject to wear and no moving parts (No maintenance) Greatly reducing of chemical expenses associated with water treatment Magnet system is a permanent solution to water treatment issues, giving immediate benefit Life and effectiveness of the system with match the operating equipment Magnetic Field Units (MFU), conservation of finite natural resources for fuel and water treatment technologies. Magnetic Field Units (MFU), conservation of finite natural resources for fuel and water treatment technologies.
water treatment Cooling Water Systems and Boiler Efficiencies Cooling Water Systems and Boiler Efficiencies Magnetic 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.
water treatment Cooling Water Systems and Boiler Efficiencies Cooling Water Systems and Boiler Efficiencies Cooling towers and condensers can create a back pressure within the turbine if the systems 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 issuesa costly balancing act never 100% effective, and scheduled cleanings are required and a certain amount of back-pressure is tolerated.
Birchwood 9% Case Study 9% Increase In Power Output Reported With HYDROLATOR 9% Increase In Power Output Reported With 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 HYDROLATORs permanent cleaning HYDROLATOR equipment has been utilized since 2000 with consistent performance results
fuel conservation MFU for conservation for fuel: MAXSYS FUEL SYSTEMS MFU for conservation for fuel: MAXSYS FUEL SYSTEMS In-line magnetic fuel treatment system (minimum 5% fuel savings assured) Pre-treat gas and oil prior to combustion to enhance combustion efficiency while lowering emissions Retrofit system - no power or maintenance required No interference to the process and combustion plant Does not affect burning equipment warranty Compatible with all burners across a range of industries
pushing and pulling strategies effect energy flow WHAT DOES THIS MEAN… Can Power Efficiency Be Improved Today? Can Power Efficiency Be Improved Today? YES IT CAN! BY PUSHING WITH CERAMIC COATINGS AND PULLING WITH MAGNETIC FIELD TECHNOLOGIES TO CREATE NEW ENERGY FLOW DYNAMICS
pushing and pulling energy flow Push And Pull Strategies For More Efficient Power Generation And Increased Revenue Income
recognizing obstacles Inherent problems are that vested interest groups are against new technologies for energy efficiency and conservation because: Inherent problems are that vested interest groups 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.
overcoming obstacles Additional Funding (Grants) And Real Incentives For: Additional 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 UsersHeavy 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.
Tim Batton, President Oxistop LLC Salem Energy Solutions Sáetech LLC Phone: Cell: Quaker Circle, Salem Industrial Park Salem, Ohio Improving power efficiency why not now! Todays use of these technologies can be the bridge to our future evolution in efficient production and conversation of our energy resources. Todays use of these technologies can be the bridge to our future evolution in efficient production and conversation of our energy resources.