Heat Recovery Presentation

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Heat Recovery Presentation
Presentation By Thermax Ltd.
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Business Profile
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ENERGY SOLUTIONS

• HIGH EFFICIENCY FIRED BOILERS AND HEATERS
• WASTE HEAT BOILERS AND HEATERS
• WASTE TO ENERGY SOLUTIONS
• VAPOUR ABSORPTION CHILLERS
• COGEN, TRIGEN

M E ENG. CO., U.K.
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ENVIRONMENT SOLUTIONS

• WATER AND WASTE WATER TREATMENT
• AIR POLLUTION CONTROL
• CHEMICALS FOR WATER AND FUEL TREATMENT

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Quality Systems
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RESEARCH DEVELOPMENT
ANNUAL SPENDING OVER USD 2 MILLION IN RD
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Co-Gen Cooling
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What is Co-Generation/ Tri- Generation ?
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CO-GENERATION
EXHAUST GAS (TO STACK)
POWER GENERATION
FUEL
STEAM/ HOT WATER
DG SET
EXHAUST GAS FROM DG
S
POWER OUTPUT
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CO-GENERATION
EXHAUST GAS (TO STACK)
POWER GENERATION
FUEL
CHILLED WATER
DG SET
EXHAUST GAS FROM DG
S
POWER OUTPUT
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TRI-GENERATION
EXHAUST GAS (TO STACK)
FUEL
STEAM/ HOT WATER FOR PROCESS
DG SET
EXHAUST GAS FROM DG
STEAM/ HOT WATER
S
ABSORPTION CHILLER
CHILLED WATER
POWER OUTPUT
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So, Co-Generation is..
Generation of at least two different forms of
energies from a single energy source
Tri-generation is Generation of at least three
different forms of energies from a single energy
source
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SANKEY DIAGRAM
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TRIGEN WITH GEN SET
With Normal DG Operation Efficiency 35
With Trigeneration Efficiency 64
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Components of Co-Generation /Tri-Generation

• POWER SIDE
• GAS TURBINE
• IC ENGINES
• STEAM TURBINE

• RECOVERY SIDE

• HRSG/ EGB

• ABSORPTION
• CHILLER

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How do the chillers work ?
1. Boiling point of the water is a function of
pressure. At atmospheric pressure water boils at
100 deg. C. When maintained at high vacuum, water
will boil and subcool itself. The boiling point
of the water at 6 mmHg (abs) is 3.7 deg. C.
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How do the chillers work ?
2. Lithium Bromide (LiBr) has the property to
absorb water due to its chemical affinity. At
higher concentration and lower temperature LiBr
absorbs water vapour (refrigerant vapour) very
effectively.
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How do the chillers work ?
4. The heating causes the solution to release
the absorbed refrigerant in the form of vapour.
This vapour is cooled in a separate chamber to
become liquid Refrigerant.
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How do the chillers work ?
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Ammonia VAM.Cycle Diagram
Out
Out
Cooling Water
Cooling Water
In
In
Subcooler
In
Brine Solution
Evaporator
Out
Control Valve
Expansion Valve
Out
Steam In
Cooling Water
Plate Heat Exchanger
Steam Out
In
Pump
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Vapour Absorption Technology

• An alternative cooling technology
• No moving parts, negligible maintenance cost.
• Saves money as uses heat as energy input
• Reduces the environmental impact as water is
  refrigerant, help reduction in CO2

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CAPABILITIES OF ABSORPTION CHILLER
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CHILLER APPLICATIONS
CHILLING APPLICATIONS
COMFORT
INDUSTRIAL
OFFICE
HOTEL HOSPITALS
SHOPPING MALLS
PROCESS COOLING
INLET AIR COOLING
INDU STRIAL AIR-CONDITIONING
REACTION COOLING
GAS TURBINE
COMPRESSOR
DG SET
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CASE STUDY
Application Gas Turbine Co-Generation

• Customer BBC, UK
• Project Office Air-Conditioning
• GT Capacity 4.9 MW
• Fuel Natural Gas
• Year of Comm 1996
• Total Chilling 1700 TR
• Heat Source Steam from HRU
• The operating savings is equivalent to US 1.7
  million approx.

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MOSER BAER ,Plant I Greater Noida, UP, India
34 MW Power 21.5 MW Cooling
E1 4 MW
E2 6 MW
E3 6 MW
E4 6 MW
E5 6 MW
E6 6 MW
HWF 485TR
HWF 485TR
HWF 485TR
HWF 170TR
HWF 485TR
EGB
EGB
EGB
EGB
EGB
DESD 800TR
DESD 800TR
DESD 800TR
DESD 800TR
DESD 800TR
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MOSER BAER ,Plant II Greater Noida, UP, India
12 MW Power 3.5 MW Cooling
E1 4 MW
E3 4 MW
E2 4 MW
EGB
EGB
EGB
Partial Recovery
DESD 648TR
DES 336TR
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Case Study Moser Baer, DelhiProject information

• Application CD manufacturing Plant
• Project CPP for CD mfg plant
• DG Make Wartsila
• DG capacity 7.62 MW X 5 Nos, 4 MW x 1 No
• Fuel Furnace Oil

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Case Study Moser Baer, DelhiBasis of Design

• Design DG Load for heat recovery and chilling
  100
• Exhaust gas quantity - 60480 Kg/Hr 31572 Kg/Hr
• Exhaust gas temp 347 Deg C 307 Deg C
• HT jacket water flow rate 150 m3/hr
• HT Jacket water temp 96 / 82 Deg C 91/85 Deg
  C
• Chilling generation from hot water machine on
  each engine 427 TR (1500kW) x 4 Nos 170 TR
  (600 kW) x 1 No
• Chilling generation from steam fired machine
  800 TR (2800 kW) x 5 Nos
• Total chilling 5878 TR (20.5MW)

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• PACIFIC MALL -DELHI
• Pacific Mall is a 5 lakh Sq.ft shopping mall near
  Sahibabad Industrial Area and is the biggest mall
  in the area, facing a large residential area of
  Delhi and Kaushambhi (Gaziabad)
• The area normally faces 6-8 Hrs of power cut
  daily and there is heavy voltage fluctuations
  thus making grid power unreliable.
• GAIL has an existing Gas network in the area.

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Operating Cost Comparison VAM Vs VCR
Parameters UOM VAM(Exhaust) VCR
Capacity TR 1000 1000
Power Consumption KW 7.5 700
Cost      
Grid Power Rs/KW 0 4.5
DG (HSD Fired) Rs/KW 0 9.5
DG (GAS Fired) Rs/KW 0 3.5
Operating Hrs Hrs/day 16 16
Operating Cost (Grid / HSD / Gas) Rs/day 540 / 1140 / 420 50400 / 106400 / 38200
Savings ( Grid / HSD / Gas) Rs/day 49860 / 105260 / 37780  49860 / 105260 / 37780 
Annual Savings Rs. Lacs / Yr 149.58 149.58
Annual Savings Rs. Lacs / Yr 315.6 315.6
Annual Savings Rs. Lacs / Yr  113.34  113.34
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Operating Cost Comparison VAM Vs VCR ON 1250 KVA
DG SET
Parameters UOM VAM(Exhaust Jacket) VCR
Capacity TR 245 TR 245 TR
Power Consumption KW 10 175
Cost      
DG Power Rs/KW 9.5 9.5
Operating Hrs/Yr Hrs/Yr 2100 2100
Operating Cost Rs/Yr 2 Lacs 35 Lacs
Savings Rs/Yr 33 Lacs 33 Lacs  
Payback Months 55/331220 55/331220  
12 hrs per day, 175 days a year of operation
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A Few International Installations

• Coca Cola, Brazil
• Johnson Johnson, USA
• Nestle Waters, USA
• Daimler Chrysler, Germany
• Utah Textiles, Bangladesh

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Some More Prestigious Clients

• Flex Industries
• Perfetti Van Mille
• American Embassy and American Embassy School,
• ITPL, Bangalore
• Cross River Mall

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One more fact to in support of TRIGENERATION
with Absorption Machine
40 of the Energy generated in the world is
consumed in Airconditioining and refrigeration
systems.
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• Thank You