ICCI 2014 Presentation : Energy Efficiency On The Move

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Dynamic Heat Exchange SolutionsEnergy efficiency in the Turkish energy sector – the

effect of using innovative heat transfer solutions

Femke Schaëfer-Wering

Istanbul – April 26th , 2014

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Topics:

• Short introduction to Bronswerk Heat Transfer®

• Why is energy efficiency improvement important?

• Improvement area’s for energy efficiency

• Solutions

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Introduction

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ICCI 2014 FACS - 26/4/2014

Our markets:

Sustainability Service & Maintenance

Power

Oil

Gas

Chemical

Air Handling

Food Processing

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What we do:

• Thermal designs:

based on:

Aspen/HTFS

HTRI

HEI

Computational Fluid Dynamics

Hysys

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What we do:

• Mechanical designs:

- ASME

- EN13445

- AD2000

- RTOD

- PD5500

- CODAP

- GOST

FEM analysis

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What we do :

• Process design:

Process optimization

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What we do :

• Equipment:

Heat exchangers

Air cooled coolers

And other process

equipment

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What we do :

• Materials:

Titanium

(Super)Duplex

Nickel-Alloy

Inconel

Other exotics

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What we do :

• Systems:

Incl. controls

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What we do :

• Site work: Erection Assembly Start up Commissioning Service

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What we do :

• Service & Maintenance: Upgrading Debottlenecking Inspection Specialist

maintenance for machines operating hazardous materials

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Our focus on innovation:

• Product development

• System solutions

• New technology

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Why is energy efficiency improvement important?

Two factors

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Factor one: 20/20/20 targets for 2020 EU members

Turkey is candidate for EU-membership

20/20/20 targets for 2020

If Turkey becomes a member of the EU they are facing these targets

too

Emission of greenhouse gases

reduced by 20% compared to 1990

Energy efficiency

increased by 20%

20% of the energy needs to be

generated sustainably

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Factor two: current status of Turkey

Growing population, economic growth, infrastructure lacking behind

Current population in

Turkey: over 76 million

Expectation for 2050

growth until: 93 million

Expectation for 2075 slow

down to: 89 million

ICCI 2014 FACS - 26/4/2014

Factor two: current status of Turkey

Growing population, economic growth, infrastructure lacking behind

Current population in

Turkey: over 76 million

Expectation for 2050

growth until: 93 million

Expectation for 2075 slow

down to: 89 million

Turkey currently: 15th

economy in the world,

Fastest growing - growth in

2013: 4,4%

Expectation for 2050: 9th

economy in the world

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Factor two: current status of Turkey

Growing population, economic growth, infrastructure lacking behind

Current population in

Turkey: over 76 million

Expectation for 2050

growth until: 93 million

Expectation for 2075 slow

down to: 89 million

Turkey currently: 15th

economy in the world,

Fastest growing - growth in

2013: 4,4%

Expectation for 2050: 9th

economy in the world

30% of energy imported

Wants to become self-sufficient:

Nuclear, geothermal, hydro, coal

and waste to energy

Patriotic duty to produce more

energy and reduce energy

consumption

Turkey Electricity Production Map

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Turkey Electricity Installed Power Chart

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Installed power capacity : 61.422 MW (30.09.2013)

Expected power increase : 50.000 MW (end of 2020)

TOTAL : 111.422 MW (end of 2020)

Area’s for improvement

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One: Newbuilds

Start at the design: reducing energy consumption of process equipment

Fans of the air cooled coolers,

condensers & combustion blowers

Pumps

Our high efficiency fans reduce

energy consumption by 50%

Our high efficiency pumps

reduce energy consumption

by 20-40%

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Two: Upgrading of Installation

High efficiency fans & pumps: increase plant capacity and efficiency

Approx. 200 kW per condenser

Approx. 600 kW combustion

blowers

Approx. 1000 kW pumps

Use these kW’s more efficiently

Increasing output

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Overall Plant Performance

Improve plant efficiency; increasing the overall efficiency by 6%

The plant efficiency is approx. 30-40%

2% is used for fans of the

condenser

6% is used for the fans of the

combustion blowers

Saving 50% on fan power

10% is used for pumps

Saving 20% on pumping power

Increase overall efficiency by 6%

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Solutions

High efficiency cooling

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Current situation:

Huge plot space requirement

High power consumption for air coolers &

combustion blowers

Big influence on CAPEX & OPEX

High efficiency cooling

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High efficiency cooling

New fan design based on

aerospace technology:

the Whizz-Wheel®

Intensified heat transfer

Over 50% reduction in

power consumption

OR

Over 30% plot space

reduction

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Benefits;

Size reduction: 30 %

Power consump. red.: 50% =

500 kW

Opex savings: € 320.000,-

/ yr

In 10 years: € 3.200.000,-

Noise reduction: 7 dB(A) Figure 3: comparative

Figure 2: high efficiency designFigure 1: standard design

High efficiency cooling

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Debottlenecking & Increasing output

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Increasing output

35% more cooling air

10-15% more production output

€ 700 million gas production

€ 70 million additional

Debottlenecking investment: € 5,5 million

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Increasing output

Restrictions:

Maximum noise level

Production capacity

down to 60%

Results:

Elimination of all

noise issues

Production up to

100%

Bonus:

56% savings in

energy consumption

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Increasing output

Restrictions:

Lower noise level or

plant shut down!

Results:

Elimination of all

noise issues

Bonus:

53% savings in

energy consumption

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Compressors/turbines

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Energy recovery from gas reduction

• Several hundreds of millions m3

pressurized gas in pipelines

• Gas at 20-80 Bar

• Increase or decrease pressure

before entering the gasturbine

Global Refining Summit 2014 FACS - 31/3/2014

Global Refining Summit 2014 FACS - 31/3/2014

Energy recovery from gas reduction

Radiax ®compressor/turbine

Global Refining Summit 2014 FACS - 31/3/2014

Global Refining Summit 2014 FACS - 31/3/2014

Radiax®compressor/turbine

Summary

Turkey needs power

Turkey needs energy efficiency

There are two area’s for improvement: Start at the design Upgrading the installation Resulting in: Overall improved plant performance

Bronswerk can help in three ways: High efficiency cooling Debottlenecking Compressors/turbines

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Summary

Yes, Bronswerk Heat Transfer can help your power plant become more energy efficient and profitable at the same time:

High efficiency

cooling

Debottlenecking Compressors/turbines

Power consumption

reduction over 50%

Elimination of all

noise issues

Energy recovery of lost

Size reduction up to

30 %

Improved production

production capacity

capacity > 100%

Size reduction up to

80%

Noise reduction:

7 dB(A)

Bonus: savings in

energy consumption

consumption

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Thank you for your attention.Questions please

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How to contact us:

www.bronswerk.com

facebook.com/bronswerk

Linkedin.com/company/bronswerk-heat-transfer

twitter.com/bronswerk

And come visit our booth in hall 10 number: A 107

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