Nansulate Wp EnergyEfficient PowerPlants

SUSTAINABLE MANUFACTURING WHITE PAPER

IMPROVING OPERATING EFFICIENCY ANDREDUCING ENERGY CONSUMPTION IN

COAL-FIRED POWER PLANT OPERATIONS

I N D U S T R I A L N A N O T E C Hwww.industrial-nanotech.com

1 9 2 5 Tr a d e C e n t e r Wa y, S t e . 1 , N a p l e s , F L 3 4 1 0 9 • p h o n e : 8 0 0 - 7 6 7 - 3 9 9 8 • w w w. n a n s u l a t e . c o m

http://www.industrial-nanotech.com

http://www.industrial-nanotech.com

http://www.nansulate.com


Table of Contents INTRODUCTION Improving Coal-Fired Power Plant Processes with Nanotechnology Coatings ............ p. 1 ..............................Nansulate® Thermal Insulation and Corrosion Prevention Coatings p. 3

TESTING DATA

.............................................................................. Chart 1: Thermal Test Data ISO 8990:1999 p. 5................................................................................... Chart 2: Corrosion Test Data GM9540P p. 6

................................... Chart 3: Thermal Conductivity Test Data BC/BP/JC issue 1, rev. C p. 7........................................... Chart 4: Resistance to CUI Test Data BC/BP/JC issue 1, rev. C p. 8

..................................................................... Chart 5: Energy Consumption Data - Henateks p. 9.................................................................................... Chart 6: Temperature Gradient Chart p. 10

PRODUCT TECHNOLOGY OVERVIEW

....................................................................................... Nansulate® Translucent High Heat p. 11......................................................................................................................... Nansulate® EPX p. 12

..................................................................................................... Nansulate® Translucent PT p. 13.................................................................................................... Nansulate® Translucent GP p. 14

NANSULATE® PERFORMANCE IN THE POWER PLANT PROCESS.......................................................................................................................... Fuel Processing p. 15

...................................................................................... Feed Water Heating and Deaeration p. 15........................................................................................................................ Boiler Operation p. 16

......................................................................................................... Steam Turbine Generator p. 17.................................................................................................................... Steam Condensing p. 17.................................................................................................................... Additional Benefits p. 18

....................................................................................................................... Additional Points p. 19

PERFORMANCE CASE STUDIES............................................................................................ Henateks - Textile Manufacturer p. 20

....................................................................... Bandvulc Tyres - Retread Tire Manufacturer p. 21....................................................................................................................... Textile Dyehouse p. 23

.......................................................................................... Sipetrol - Oil and Gas Subsidiary p. 24

BEHIND THE TECHNOLOGY........................................................................................... Basics of how Nansulate® Works p. 25

SUMMARY AND CONCLUSIONS............................................................................ Reducing Energy Costs with Nansulate® p. 26

I n d u s t r i a l N a n o t e c h , I n c . I m p r o v i n g P e r f o r m a n c e o f C o a l - F i r e d P o w e r P l a n t s

T O C - 1

IntroductionImproving Coal-Fired Power Plant Processes with Nanotechnology Coatings

Coal-Fired and other fossil fuel power plants rely on the conversion of heat energy from combustion into mechanical energy, when then operate an electrical generator. By utilizing nanotechnology coatings for insulation and corrosion control of key heat generating and transport equipment, a plant can significantly reduce costs associated with energy generation as well as equipment maintenance. Additionally, reduction in equipment surface temperatures can also improve personnel safety.

Coal-Fired Power Plant Operations

The conversion from coal to electricity takes place in three stages. Stage 1: The first conversion of energy takes place in the boiler. Coal is pulverized and mixed with hot air and blown into the firebox of the boiler. It is burnt in the boiler to produce steam. Boilers produce steam at temperatures of up to 1,000 degrees F and under pressures up to 3,500 pounds per square inch. Stage 2: The second stage is the thermodynamic process. The heat from combustion of the coat boils water in to produce steam, the steam is then piped into a turbine. The steam is then condensed and pumped back into the boiler to repeat the cycle. Stage 3: In the third stage, the rotation of the turbine powers the generator to produce electricity.

Generation of electricity in a coal-fired steam station is similar to a nuclear station. The difference is the source of heat. The burning of coal replaces fissioning, or splitting , of uranium atoms as the source of heat. The heat turns water to steam in steam generators. The steam is then used to drive turbine generators.

Throughout this process there is much potential for heat loss and thus energy loss. This includes:

1. Heat loss through exterior of boiler

2. Heat loss through steam pipes

3. Heat loss through Turbine chamber

4. Heat loss through heat exchangers


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Power Station Steam PipesSteam TurbineSteam Boiler for Power Generation

By using an insulation coating that can be painted onto each part of the heat generation flow (boiler, steam pipes, heat exchanger, turbine chamber) the entire system becomes more energy efficient, and less energy is used to reach the same process temperature. An insulation coating offers an insulation and protective solution for large equipment or surfaces that are typically not easy to insulate by traditional means (such as fiberglass or rock wool insulation).

Secondarily, traditional forms of insulation are highly subject to infiltration of moisture which rapidly reduces their insulating benefit and contributes to corrosion of the underlying surface. This phenomenon is known as corrosion under insulation (CUI), and it requires costly regular inspection and replacement of pipes and other equipment. Nansulate® nanotechnology based insulation coatings not only insulate effectively in a thin layer, they also are resistant to moisture infiltration, which means:

1. Insulation coatings insulate effectively, and retain that insulating ability over time due to being moisture resistant.

2. Insulation coatings prevent corrosion and allow visual inspection of the underlying surface.

3. Insulation coatings offer both a more consistent and more cost effective way to insulate manufacturing equipment.

4. Can be applied while the lines and equipment are in operation, reducing costly downtime.


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Corrosion of steam pipes caused by traditional insulation

Nansulate® nanotechnology based clear coatings used to insulate and prevent corrosion of steam pipes

Nansulate® Thermal Insulation and Corrosion Prevention Coatings

Nansulate® coatings, created by Industrial Nanotech, Inc., offer combined benefits that were not possible before with conventional coatings. They offer an energy efficient and environmentally friendly method to insulate, prevent corrosion and even reduce carbon emissions on all types of equipment such as boilers, steam lines, heat exchangers, processing tanks, piping and more.

Early adopting plant managers are reaping the rewards of thinking big with a technology focused on the small. Nanotechnology is development at the atomic, molecular or macromolecular range of 1-100 nanometers to create materials that have novel properties. In the past, nanotechnology was closely synonymous with high cost and expensive, especially as new products entered the market and economies of scale had not been reached. But over the last five years, the technology has gone from the lab to plants and factories around the world in the form of an industrial coating that provides a unique combination of benefits, one of which is affordability. Due to the affordability of the technology as well as its performance qualities, the average payback period for the technology is between 6-18 months, with most customers experiencing payback in less than 1 year.

The technology in Nansulate® industrial coatings is one that incorporates a nanocomposite with extremely low thermal conduction and a hydrophobic nature into a water-based acrylic latex, giving these coatings the ability to provide thermal insulation, corrosion resistance and mold resistance. In ISO standard testing for thermal properties, the Nansulate® coatings were shown to block 34.8% of thermal transfer (see chart 1) (at a thickness of approx. 7 mils), and have passed 24 cycles of the GM9540P Accelerated Corrosion Test (see chart 2). The coating has also been tested on pipes according to BP (British Petroleum) standards for both Thermal Conductivity (see chart 3) and Corrosion Under Insulation (see chart 4) and was shown to retail performance over time and adhere well with no loss of adhesion when subject to the cyclical environment testing.

Whether used on hot equipment such as heat exchangers, boilers, tanks and piping or on the walls and ceilings of a building to reduce heating and cooling costs, the technology offers a novel combination of benefits that can quickly decrease energy costs in plant facilities.

Several companies who have explored and adopted Nansulate® are already experiencing significant cost and energy savings, increases in asset longevity and simply implemented worker safety improvements for high heat equipment. An extensive study was done at Henateks Textile facility, where their fuel is natural gas; they have several meters all around the factory that record daily usage for separate areas of the plant and plant equipment. They calculate their specific consumption of natural gas per kg of fabric dyed; their production is almost consistently the same type of fabric over the years, so they take the natural gas usage divided by production as the specific consumption factor, which differs by only 5 % from average depending on whether it is summer or wintertime. They compared the previous years’ average readings with the readings after they used Nansulate® coating on their machines, steam boilers, steam pipes, and heat exchangers; their monthly figures varied from a -15% decrease to a -25% reduction


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in energy use, with an average decrease of -20%. A deeper analysis showed that the savings are even higher for steam lines and steam using machinery; approximately 30% reduction in energy use.

"Because of global warming, our duty is to make use of energy as efficiently as possible; wasted energy is wasted national wealth. This is why I highly recommend this technology to all of (the) textile industry and other heat using industries." stated Eyüp Sözdinler of Henateks A.S.

Heneteks ended up with a payback period of only seven months. After an investment of $200,000 for the coatings, they are saving an average of $600,000 per year in energy costs. (see chart 5)


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Testing DataChart 1

THERMAL TEST DATA

Standard Test Method for Steady-State Thermal Performance of Building Assemblies (UNI EN ISO 8990:1999)

Testing was done by the accredited laboratory Istituto di Richerche E Collaudi - a certifying body for the Italian Government.

Results:

Thermal flow, measured in watts, through the wall section coated with Nansulate® was reduced by 34.80%

Thermal resistance (1/U), measured in m2*k*w1, of the wall section coated with Nansulate® was increased by 28.98%

Heat loss in Watts Heat loss in btu

Uninsulated surface 32.003 109.198 Btu (IT)/Hour

Same surface with Nansulate® 20.860 71.178 Btu (IT)/Hour

Uncoated Wall Nansulate® Coated Wall Difference

Thermal Flow through measured area

32.0030 watts 20.8605 watts -11.1425 watts34.8% difference

Coefficient of thermal transmittance( Uvalue)

1.6179 W/m2 K 1.2544 W/m2 K -0.3635 W/m2 K22.47% difference

Thermal Resistance 1/U 0.6181 m2*k*w 0.7972 m2*k*w 0.179128.8% difference


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Chart 2


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Chart 3

THERMAL CONDUCTIVITY

Thermal conductivity exposure 60°C to 130°C

The externally coated pipe was filled with Shell Thermal B oil with four internal and four

external thermocouples. One internal and one external thermocouple were positioned so they were at the same position to enable the measurement of the temperature difference. The sets of thermocouples were at different depth and equally spaced around the pipe. The oil was heated to 60°C and held for 24 hours then increased to 90°C and held for 24 hours then increased to 110°C and held for 24 hours then increased to 130°C.


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Chart 4

RESISTANCE TO CUI

Resistance to CUI exposure at 130°C internal temperature

The externally coated pipe was filled with Shell Thermal B oil with four internal and four

external thermocouples. One internal and one external thermocouple were positioned so they were at the same position to enable the measurement of the temperature difference. The sets of thermocouples were at different depth and equally spaced around the pipe. The oil was heated to 130°C and held for 100 days. During the 100 days the coating was sprayed with artificial seawater periodically over every 24 hours. Before the exposure test the coating has 020mm holidays milled through the coating to the substrate at three locations and saw cuts were made through the coating at the top and bottom of the cornered joint.


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Chart 5


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Chart 6


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Product Technology Overview

NANSULATE® TRANSLUCENT High Heat

Direct to metal - Boilers, steam pipes, containers, heat exchangers, etc...

Product Description: Nanotechnology-based thermal insulation coating with additional benefits of moisture resistance and corrosion prevention. For applications up to 400F (204C)

Main Product Benefits

✓ Excellent thermal insulation in a thin film coating

✓ Resistance to moisture

✓ Maintains integrity and performance over time

✓ Protects against UV rays

✓ Prevents corrosion

✓ Class A Fire Rating (per ASTM E84)

✓ Low VOC (100 g/L)

✓ Reduces surface temperature of hot pipes and equipment

✓ Clear coating allows visual inspection of pipe without removal

✓ Easily applied with conventional paint spray equipment at low pressure

✓ Tested to ISO standard for thermal performance of building assemblies, and shown to block thermal flow by 34.8% and increase thermal resistance by 28.8%

✓ Breathable (5 perms/inch @ 23 deg. C)

✓ Eliminates corrosion under insulation (CUI) issues


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Nansulate® High Heat is applied over steam pipes and valves.

Nansulate® High Heat is applied with typical paint equipment, brush, roller, sprayer

NANSULATE® EPX

FOR HARSH ENVIRONMENTS AND THICKER APPLICATION NEEDS - Use over primer coat of Nansulate® High Heat or PT when using on metal, can be used over concrete, wood, plastic and other materials. Use for pipes, manufacturing equipment, boilers, heat exchangers and more.


✓ Excellent thermal insulation


✓ Chemical resistance (resistant to splash contact of acids, bases and fuels)

✓ Flame resistance


✓ Not subject to degradation due to environmental factors


✓ Low VOC (60 g/L), non-toxic

✓ Reduces surface temperature of hot surfaces

✓ Easily applied with texture sprayer

✓ Allows for thicker application

✓ Good sag resistance


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Nansulate® EPX (blue version) applied over steam line in chemical plant.

Nansulate® EPX (grey version) applied to textile dyeing machines.

NANSULATE® TRANSLUCENT PT

Direct to metal - Water pipes, duct work, metal buildings, etc...

Product Description: Nanotechnology-based thermal insulation coating with additional benefits of moisture resistance and corrosion prevention. For applications up to 256F (125C)
















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Nansulate® PT is applied to structural aluminum panels

Nansulate® PT is applied to hot water pipeline

NANSULATE® TRANSLUCENT GP

Building envelope - Walls, ceilings, non-metal surfaces.

Product Description: Nanotechnology-based thermal insulation coating with additional benefits of moisture resistance and mold resistance. For building envelope applications
















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Nansulate® GP is being applied via roller to painted building surface

Nansulate® GP applied to interior wood walls and ceiling

Nansulate® Performance in Power Plant Process

Power Generation Process

Each stage of the power generation process works together to turn fuel into electricity, and each has potential for reducing heat/energy loss.

Fuel Processing

Coal is prepared for use by crushing the rough coal to pieces less than 2 inches (5 cm) in size. The coal is then transported from the storage yard to in-plant storage silos by rubberized conveyor belts at rates up to 4,000 short tons per hour.

In plants that burn pulverized coal, silos feed coal pulverizers (coal mills) that take the larger 2-inch pieces, grind them to the consistency of face powder, sort them, and mix them with primary combustion air which transports the coal to the furnace and preheats the coal to drive off excess moisture content. A 500 MWe plant may have six such pulverizers, five of which can supply coal to the furnace at 250 tons per hour under full load.

In plants that do not burn pulverized coal, the larger 2-inch pieces may be directly fed into the silos which then feed the cyclone burners, a specific kind of combusted that can efficiently burn larger pieces of fuel.

NANSULATE® PERFORMS:

Nansulate® coating can be used externally to insulate areas in which the coal is preheated to drive off excess moisture content.

Feed water heating and deaeration

The feed water used in the steam boiler is a means of transferring heat energy from the burning fuel to the mechanical energy of the spinning steam turbine. The total feed water consists of recirculated condensate water and purified makeup water. Because the metallic materials it contacts are subject to corrosion at high temperatures and pressures, the makeup water is highly purified before use. A system of water softeners and ion exchange demineralizers produces water so pure that it coincidentally becomes an electrical insulator, with conductivity in the range of 0.3–1.0 microsiemens per centimeter. The makeup water in a 500 MWe plant amounts to perhaps 20 US gallons per minute (1.25 L/s) to offset the small losses from steam leaks in the system.


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http://en.wikipedia.org/wiki/Conveyor_belt

http://en.wikipedia.org/wiki/Conveyor_belt

http://en.wikipedia.org/wiki/Pulverizer

http://en.wikipedia.org/wiki/Pulverizer

http://en.wikipedia.org/wiki/Talcum_powder

http://en.wikipedia.org/wiki/Talcum_powder

http://en.wikipedia.org/wiki/Cyclone_furnace

http://en.wikipedia.org/wiki/Cyclone_furnace

http://en.wikipedia.org/wiki/Steam

http://en.wikipedia.org/wiki/Steam

http://en.wikipedia.org/wiki/Steam_turbine

http://en.wikipedia.org/wiki/Steam_turbine

http://en.wikipedia.org/wiki/Corrosion

http://en.wikipedia.org/wiki/Corrosion

http://en.wikipedia.org/wiki/Water_softener

http://en.wikipedia.org/wiki/Water_softener

http://en.wikipedia.org/wiki/Ion_exchange

http://en.wikipedia.org/wiki/Ion_exchange

http://en.wikipedia.org/wiki/Electrical_insulation

http://en.wikipedia.org/wiki/Electrical_insulation

http://en.wikipedia.org/wiki/Electrical_conductivity

http://en.wikipedia.org/wiki/Electrical_conductivity

http://en.wikipedia.org/wiki/Siemens_%28unit%29#Definition

http://en.wikipedia.org/wiki/Siemens_%28unit%29#Definition

The feed water cycle begins with condensate water being pumped out of the condenser after traveling through the steam turbines. The condensate flow rate at full load in a 500 MWe plant is about 6,000 US gallons per minute (400 L/s).

The water flows through a series of six or seven intermediate feed water heaters (fig1), heated up at each point with steam extracted from an appropriate duct on the turbines and gaining temperature at each stage. Typically, the condensate plus the makeup water then flows through a deaerator that removes dissolved air from the water, further purifying and reducing its corrosivity.


Nansulate® Translucent High Heat coating applied to the exterior of the feed water heaters, allows them to retain more heat, thus it uses less energy for the heat process.

Boiler Operation

The boiler is a rectangular furnace about 50 feet (15 m) on a side and 130 feet (40 m) tall. Its walls are made of a web of high pressure steel tubes about 2.3 inches (58 mm) in diameter.

Pulverized coal is air-blown into the furnace from fuel nozzles at the four corners and it rapidly burns, forming a large fireball at the center. The thermal radiation of the fireball heats the water that circulates through the boiler tubes near the boiler perimeter. The water circulation rate in the boiler is three to four times the throughput and is typically driven by pumps. As the water in the boiler circulates it absorbs heat and changes into steam at 700 °F (371 °C) and 3,200 psi (22 MPa). It is separated from the water inside a drum at the top of the furnace. The saturated steam is introduced into superheat pendant tubes that hang in the hottest part of the combustion gases as they exit the furnace. Here the steam is superheated to 1,000 °F (500 °C) to prepare it for the turbine.


Nansulate® Translucent High Heat coating applied to the exterior of the boiler reduces heat loss and increases efficiency of the system, in addition to providing resistance to corrosion. The insulation is extremely moisture resistant, so it holds up well in steam operations and humid environments.


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Fig 1

http://en.wikipedia.org/wiki/Surface_condenser


http://en.wikipedia.org/wiki/Deaerator

http://en.wikipedia.org/wiki/Deaerator

http://en.wikipedia.org/wiki/Furnace

http://en.wikipedia.org/wiki/Furnace

http://en.wikipedia.org/wiki/Coal_dust

http://en.wikipedia.org/wiki/Coal_dust

http://en.wikipedia.org/wiki/Thermal_radiation

http://en.wikipedia.org/wiki/Thermal_radiation

http://en.wikipedia.org/wiki/Boiler

http://en.wikipedia.org/wiki/Boiler

http://en.wikipedia.org/wiki/Fahrenheit

http://en.wikipedia.org/wiki/Fahrenheit

http://en.wikipedia.org/wiki/Celsius

http://en.wikipedia.org/wiki/Celsius

http://en.wikipedia.org/wiki/Pounds_per_square_inch

http://en.wikipedia.org/wiki/Pounds_per_square_inch

http://en.wikipedia.org/wiki/Pascal_%28unit%29

http://en.wikipedia.org/wiki/Pascal_%28unit%29

http://en.wikipedia.org/wiki/Superheat

http://en.wikipedia.org/wiki/Superheat

Steam Turbine Generator

The turbine generator consists of a series steam turbines interconnected to each other and a generator on a common shaft. There is a high pressure turbine at one end, followed by an intermediate pressure turbine, two low pressure turbines, and the generator. As steam moves through the system and loses pressure and thermal energy it expands in volume, requiring increasing diameter and longer blades at each succeeding stage to extract the remaining energy. The entire rotating mass may be over 200 metric tons and 100 feet (30 m) long. It is so heavy that it must be kept turning slowly even when shut down (at 3 rpm) so that the shaft will not bow even slightly and become unbalanced. This is so important that it is one of only five functions of blackout emergency power batteries on site.

Superheated steam from the boiler is delivered through 14–16-inch (360–410 mm) diameter piping to the high pressure turbine where it falls in pressure to 600 psi (4.1 MPa) and to 600 °F (320 °C) in temperature through the stage. It exits via 24–26-inch (610–660 mm) diameter cold reheat lines and passes back into the boiler where the steam is reheated in special reheat pendant tubes back to 1,000 °F (500 °C). The hot reheat steam is conducted to the intermediate pressure turbine where it falls in both temperature and pressure and exits directly to the long-bladed low pressure turbines and finally exits to the condenser.


Nansulate® Translucent High Heat coating applied to the exterior of the turbine chamber, reduces heat loss and helps keep a more consistent temperature throughout the power generation process.

Steam Condensing

The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be pumped. If the condenser can be made cooler, the pressure of the exhaust steam is reduced and efficiency of the cycle increases. The condenser is usually a shell and tube heat exchanger commonly referred to as a surface condenser. Cooling water circulates through the tubes in the condenser's shell and the low pressure exhaust steam is condensed by flowing over the tubes.


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http://en.wikipedia.org/wiki/Turbine

http://en.wikipedia.org/wiki/Turbine

http://en.wikipedia.org/wiki/Revolutions_per_minute

http://en.wikipedia.org/wiki/Revolutions_per_minute

http://en.wikipedia.org/wiki/Temperature

http://en.wikipedia.org/wiki/Temperature

http://en.wikipedia.org/wiki/Pressure

http://en.wikipedia.org/wiki/Pressure

http://en.wikipedia.org/wiki/Rankine_cycle

http://en.wikipedia.org/wiki/Rankine_cycle

http://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger

http://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger




Application of Nansulate® coatings throughout the power generation process on heat producing equipment such as boilers, feeders, steam pipes and other heat generation and transport equipment that produce the heat energy can significantly reduce the amount of energy used in the entire process. In comparable processes, the insulation coating has reduced energy consumption by 15% to 25% over all.

The coatings can also be applied while equipment is in operation, meaning there is no downtime necessary for installation.

The coating reduces energy consumption on the components by:

1) Insulation of the pre-treatment area/furnace where coal is heated to reduce moisture content causes less energy to be used to maintain desired pre-treatment temperature.

2) Insulation of the feed water heaters reduce the amount of steam needed to heat the water to the desired temperature, and also protects the exterior from corrosion.

3) Insulation of the boiler which produces the steam, means that less fuel is used to produce the same amount of steam energy.

4) Insulation of the chamber which holds the steam turbine generator reduces any heat loss through the chamber walls.

5) Insulation of the steam pipes, heat exchangers and similar system components, means that more of the energy produced by the boiler is being delivered to the end power generation process and less is lost through the walls of the steam pipes and other equipment.

Additional benefits for reduced energy consumption include reducing the surface temperature of all components which:

1) Improves personnel safety by reducing chance for burn injuries. (see chart 6 for correlation of surface temperature reduction to number of coats and beginning surface temperature)

2) Reduces the energy used to cool the facility. As less heat is expelled into the environment from the steam pipes, boiler, and other heat producing equipment, the air conditioning unit uses less energy to cool the heat intensive manufacturing areas.


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Additional benefits related to equipment repair and maintenance include:

1) Prevention of corrosion of surfaces means that there is less downtime due to replacement and less replacement cost.

2) Clear coatings allow for visual inspection of surfaces without costly removal and replacement of insulation.

3) All components operation more effectively due to reducing thermal loss, thus lifespan should be increased.

Additional points:

1) Sustainable Technology - Low VOC, non-flammable, non-toxic. Reduces energy consumption and is environmentally friendly.

2) Affordability + Significant Savings - The combination of product affordability plus exceptional energy saving benefit offer a typical customer payback period (documented by case studies) of less than 1 year.

3) Retrofit Solution - Application of insulation coatings allow easy retrofit of existing equipment and plants, which is typically significantly less expensive than replacing equipment.

4) Availability - The coatings are available through the manufacturer, Industrial Nanotech, Inc. (www.nansulate.com) or through commercial supplier Grainger. (www.grainger.com).


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http://www.grainger.com

http://www.grainger.com

Performance Case Studies

Case Study - Henateks, textile manufacturer for Nike, Adidas, Reebok

Product used - Nansulate® Translucent High Heat

Application on Steam Boiler, pipes, heat exchanger, dye machines

Customer Energy Savings in 2007: $392,275.15 USD

(application was ongoing)

Customer Energy Savings in 2008: $460,161.90 USD

Material Cost for Product: $200,000 USD

Application/Installation Cost for Project: $100,000 USD

Payback Period: 7 months

Energy costs reduced by average of 20%

2007 Liquid Natural Gas Savings = 1,114,152. Sm3

2008 Liquid Natural Gas Savings = 1,097,447. Sm3

(factory not at full production capacity in 2008)

Average Monthly Cost Savings Provided:

$35,518.00 USD


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Case Study - Bandvulc Tyres, one of the leading suppliers of commercial tires to the transport industry


Application on heat exchanger plates

SOLUTION: "Bandvulc Tyres Ltd. applied Nansulate to the exterior of a heat exchanger plate. The first coat was applied thinly and left to set for just over 20 days. After this period, the coats were applied more liberally up until the 8th coat. The 8th coat result now shows a temperature difference of roughly 30 degrees C."

-Calum Williams, Bandvulc Tyres Ltd.www.bandvulc.com

Note: Study was done before all 8 coats had completely cured. Nansulate reaches its full insulation ability after full cure.


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http://www.bandvulc.com/

http://www.bandvulc.com/

Case Study - Bandvulc Tyres, one of the leading suppliers of commercial tires to the transport industry

continued......


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Case Study - Textile Dyehouse for Sports Apparel Manufacturers


Application on Dye Machines, Industrial Dryers, LNG Burners, Steam Pipes, Valves

Customer Energy Savings - first year: $100,000 USD

Material Cost for Project: $40,000 USD

Payback Period: 4 months

Energy costs reduced by average of 10%

Additional Solution, Dye lot consistency was improved due to Nansulate® providing a more effective insulation that retain its insulating ability consistently over time.

Average Monthly Cost Savings Provided: $8,333.00 USD


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Case Study - Sipetrol Argentina, Oil & Gas Subsidiary of ENAP

Product used - Nansulate® Translucent PT

Application on offshore oil platform pipeline

Solution Provided: Temperature Reduction of 32F (18C)

Sipetrol coated a pipeline on their AM6 offshore platform to reduce heat loss during pipeline transportation of petroleum product.

Application: Nansulate® PT was applied in three coats for a total average thickness of 350 microns to exterior of the above water pipeline. Surface temperature of pipeline was measured to determine reduction of heat loss from petroleum products.

Prior to application, the average temperature of the pipeline exterior was 140F (60C). With Nansulate® PT the average temperature of the pipeline exterior was 107.6F (42C) resulting in significant energy savings.

Many more case studies are available at www.nansulate.com


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Behind the TechnologyBasics of How Nansulate® Works

Nansulate® coatings are a patented insulation technology that incorporates a nanocomposite called Hydro-NM-Oxide, a product of nanotechnology. This material is documented as having one of the lowest measured thermal conductivity values. Nansulate® is able to insulate in a thin layer due to the unique make up of the Hydro-NM-Oxide nanocomposite. Its internal, nanoscale architecture consists of a network of tunnels, which help to reduce the heat energy that is flowing through it.

Nansulate® insulates by means of low thermal conduction (or by reducing conduction of heat energy through the material). It does not insulate by means of reflectivity. This means that it is equally effective at reducing thermal transfer in interior applications.


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The Science:1. Heat always transfers to cold.

No Insulation

Nansulate® Insulation Coating

Summary and ConclusionsReducing Energy Costs with Nansulate®:

Coal-fired power plants can significantly increase operating efficiency and reduce energy costs affordably and immediately by utilizing Nansulate® nanotechnology based coatings for both insulation and corrosion control. Energy costs can be reduced by approximately 10% to 25% depending upon application, and based upon both real world applications and independent testing.

Facilities can use the coatings for:

1. Equipment that does not currently have a suitable insulation option: This can include boilers, feed water heaters, furnaces, and other equipment that due to size or area limitations cannot be insulated with traditional forms of insulation.

2. Replacement for traditional insulation (fiberglass, pipe wrap, rock wool, etc..). The insulation coating can be used to replace traditional insulation and offers a clear alternative that also prevents corrosion rather than causing it.

Equipment that can be insulated for reducing energy costs:

1. Pre-treatment furnace

2. Feed water heaters

3. Boilers

4. Steam Pipes

5. Heat Exchangers

6. Steam Turbine Generator Compartment

Other opportunities for energy savings from insulation of:

1. Building Envelope: Insulation of walls, ceilings and roofs to reduce energy used for heating and cooling buildings.

2. Ductwork: Insulation of A/C ductwork to reduce energy used for cooling.

3. Cold water pipes: Insulation and corrosion prevention for cold water piping.


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Other cost saving benefits:

1. Prevents Corrosion: Reduces maintenance and replacement costs of equipment due to corrosion

2. Personnel Safety: Helps prevent worker burns by reducing surface temperature of hot equipment and pipes.

3. Short Payback: Typical customer payback is less than one year.

4. Can be applied while the lines and equipment are in operation, reducing costly downtime.

Due to the heat intense processing costs of coal-fired power generation, facilities stand to benefit from substantial decreases in energy efficiency by reducing the heat/energy loss for those processes. The bottom line is that new technology can convert formerly fixed energy costs to manageable. Allowing power plants to lower energy costs and significantly improve profit margins.

Nansulate® technology is a poster child for sustainable manufacturing. Besides saving energy, the coatings are also considered “green” and are low VOC. There is even a version that is NSF registered (formerly USDA registration) as safe for incidental food contact surfaces, which makes it suitable for use in food and beverage manufacturing applications. In addition to coatings which are used on boilers and heat equipment, there are also insulation coatings for walls, ceilings and roofs of buildings, for a total facility energy efficiency solution.

Reducing heat loss to increase efficiency sounds so simple, and the concept is just that. Insulating all components within the power generation process with a thermal barrier coating means that more of the heat produced by the coal and boiler is converted to energy and thus the end cost per kwh generated is reduced.

New technology typically comes with a high price tag, but Nansulate® coatings are an exception to that mindset. Applications can be done while the lines are running and the ability to significantly reduce costs without a large capital expenditure make this technology a unique and viable option for the power industry.


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