1. Enhancing Energy Efficiency in Industry with Gas Turbine CHP
Stella Spazzoli
Application Engineer
OPRA Turbines
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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
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