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Enhancing Energy Efficiency in Industry with Gas Turbine CHP

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Presentation on theme: "Enhancing Energy Efficiency in Industry with Gas Turbine CHP"— Presentation transcript:

1 Enhancing Energy Efficiency in Industry with Gas Turbine CHP
Stella Spazzoli Application Engineer OPRA Turbines Mobile: (0) Website: 1

2 Contents Introduction to OPRA Turbines
Combined Heat and Power (CHP) in UK Alternative fuel Opportunities Energy intensive sectors Case Study

3 Contents Introduction to OPRA Turbines
Combined Heat and Power (CHP) in UK Alternative fuel Opportunities Energy intensive sectors Case Study

4 Introduction: OPRA Turbines
OPRA was established in Hengelo (NL) in 1991 OPRA became part of Energas Group in 2017 OPRA provides on-site gas turbine driven energy solutions in the power range < 3 MW OPRA has market success for Oil & Gas and industrial and commercial CHP applications OPRA sold 130+ OP16 gas turbines accumulating 2+ million operating hours OPRA is ISO 9001 and GOST certified, OP16 is DNV-GL approved for marine and offshore applications

5 Packaged Gas Turbine solution with a small footprint
Reduction gear Air filtration and ventilation Dual-fuel & low emissions combustors Control panels OP16 Gas turbine Bearings in cold part of engine Fuel system Generator OP16 Gas Turbine OP16 Gas Turbine Package

6 Contents Introduction to OPRA Turbines
Combined Heat and Power (CHP) in UK Alternative fuel Opportunities Energy intensive sectors Case Study

7 Energy Demand in the UK Energy-intensive industry shares of total industrial sector energy consumption (OECD) Source: Electricity Costs of Energy Intensive Industries (Fraunhofer, ECOFYS)

8 The CHP opportunity in the UK
Electricity Prices by Country 1.9 MWel 6 MWth Gas Burner 8 MWth WHRG 2015 2016 2017 CHP Installed Capacity Payback time 2 to 3 years Source: Eurostat data, Small-Medium Industry with annual consumption MWh

9 Gas Turbine CHP: Key Benefits
Independency Security of supply Power, steam, hot air, cooling on site Reliability Robust design Packaged solution Availability Low maintenance 42500 hours between major overhaul Profitability Lower energy costs Lower production costs Higher cost savings

10 Contents Introduction to OPRA Turbines
Combined Heat and Power (CHP) in UK Alternative fuel Opportunities Energy intensive sectors Case Study

11 Alternative Fuel Opportunity: Biogas
Covered anaerobic lagoon digester Plug flow digester Complete mix digester Typical Composition 𝐶𝐻 4 , 𝐻 2 𝑂, 𝐻 2 𝑆, 𝑂 2 , 𝑁𝐻 3 , 𝐻 2 , 𝐶𝑂 2 , 𝑁 2 , LHV 20 MJ/m3 Feedstock Organic waste Municipal waste Agricultural waste Challenges Gas compressor Impurities Biogas

12 Combustion Technology: OP16-3C
Low emissions 5x Volume to ensure proper combustion Advanced diffusion type combustor Biogas Syngas Pyrolysis oil Industrial tail gases Gaseous fuel between 5-25 MJ/kg Blend low LHV fuel with natural gas Start up on high LHV Fuels High calorific fuel as back up Dual- and bi- fuel operation Conventional combustor Low calorific value combustor

13 Contents Introduction to OPRA Turbines
Combined Heat and Power (CHP) in UK Alternative fuel Opportunities Energy intensive sectors Case Study

14 Breweries: Energy Consumption
Heat Chiller Hot water Electricity Grains disposal & waste water 𝑪𝑶 𝟐 Recovery plant Produced through fermentation of wheat Energy intensive process Energy accounts for 3-8% of production costs Beer production Energy saving technologies (CHP) Waste water treatment (biogas) Gasification of insoluble grains Environmental impact Annual production ≤ 1.5 mhL of is good fit for 1 OP16 Annual production > 1.5 mhL is good fit for 1-2 OP16 Size match Beer is produced through fermentation of barley or wheat. Energy is needed as electricity and as heat (hot water and steam). Beer is made by extracting the sugars from grains. The first step consists in harvesting the grains, which are then heated, dried and cracked. The malt is milled and treated. Then, the malt and adjuncts are mixed with hot water in a mash mill. The undissolved grains are separated and disposed. The wort, a sticky liquid, is separated from the mash and the water can be sent to a waste water treatment unit. The wort is boiled with hops and then the liquid is cooled to 8-20°C and filtered. During fermentation, yeast is added to the wort. The beer which is obtained after the first fermentation is “maturated” and stored. Next, it is filtered to eliminate bacteria, and pumped to the bright beer tank. The beer is bottled and carbonated, acquiring the sparkling features. Lastly, the equipment must be cleaned deeply, through the Clean In Place (CIP), which uses steam for sterilizing all of the pieces of equipment used.

15 Dairies: Energy Consumption
Dairies are typically located in a dedicated farm Energy intensive process Energy accounts for 2-3% of production costs Dairies production Possibility for Cogeneration and Trigeneration Environmental Impact Annual Production ≤ 210 M kg of milk is good fit for 1 OP16 Annual production > 210 M kg of milk is good fit for 1-2 OP16 Size Match Reception Storage Filtration Clarification Standarization Pasteurization Homogenization Cooling Packaging Refrigerated Electricity Heat *Liquid Milk Figure 3.1 illustrates the typical process for producing fluid milk. Upon entering the facility, raw milk is (sometimes) clarified and then cooled a few degrees prior to being transferred to cooled storage tanks. To produce pasteurized milk, the most common type of milk in the U.S., the milk is standardized and pasteurized, with the homogenization step usually occurring prior to the milk being cooled back down (Brennan 2006). The cooled milk is then packaged and kept in refrigerated storage until shipment. Ultra high temperature milk (UHT), which is quite common in Europe, replaces the pasteurization step with a sterilization step. The milk is then aseptically packed into sterilized packaging. Due to its long shelf life, UHT milk is commonly stored at room temperature (Wastra et al. 2006). Heat Electricity CIP

16 OP16 integration in the system
GT Exhaust Water/Steam Electricity Ambient air GT Fuel Legend Electricity (utilities) Electrical chiller 1.8 MW WHRB 8.9 kg/s at 570C Hot water 6.5 t/h steam Fuel 8.9 kg/s at 570C Hot water steam Electricity (utilities) 1.8 MW WHRB Chiller Cold air Fuel OP16 Gas Turbine CHP OP16 Gas Turbine Package CCHP

17 Contents Introduction to OPRA Turbines
Combined Heat and Power (CHP) in UK Alternative fuel Opportunities Energy intensive sectors Case Study

18 Case Study – Tissue Mill in Italy
Outdoor Installation Temperature between -10⁰C and +35⁰C Site installation 1.8 MWe and 8.9 kg/s exhaust gas at 570⁰C 24/7 Operation connected to grid Performance OP16 Exhaust to the Yankee Hood drier and WHRB Inlet air to OP16 is cooled using absorption chiller System configuration Payback time 2 years 30% Energy savings >90% CHP efficiency Energy savings Fivizzano (Italy), June 2017

19 Conclusions Who What When Where Why Highly energy intensive processes
Chemicals, food processing, pulp & paper Who Small Gas Turbines based CHP Alternatives to traditional power and heat generation What OPRA since 1991 Gas Turbine CHP is now When UK and Ireland Italy, Germany, USA Where Energy costs reduction, quick payback Emissions reduction Availability of power and heat Why

20 E-mail: s.spazzoli@opra.nl Website: www.opraturbines.com
Thank You Stella Spazzoli Application Engineer OPRA Turbines Mobile: (0) Website:


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