ENERGY ON GLASS ALL IN ONE

Transcription

1 ENERGY ON GLASS WASTE HEAT RECOVERY HEAT EXCHANGER ORC TURBINETOO COGENERATION TRIGENERATION STEAM & SUPERHEATED W WATER TREATMENT EMISSION MONITORING SYSTEM ORC TURBINE HEAT EXCHANGER COGENERATION TRIGENRATION DEDUSTING SOx NOx ABATEMENT WATER TREATMENT TREATMENT EMISSION MONITORING CONTROL COMPRESSOR LINE MANAG CERAMIC FILTRATION WASTE HEAT RECOVERY - HEAT EXCHA HEAT EXCHANGER ORC EMISSION STEAM & SUPERHEATED WATER GLASS AUTOMATION ENERGY ALL IN ONE

2 QUALITY IS NEVER AN ACCIDENT. BDF INDUSTRIES, SINCE 1906.

3 PRODUCT LINES MELTING BDF industries Melting product line includes the complete glass melting and conditioning technologies for design and supply of furnaces, working end & forehearths. The range of products includes also the relevant equipment like oil and gas burners and firing system, air and exhaust reverse valve, batch chargers, forehearth glass mixers etc. BDF Industries furnaces are engineered by high level of customization with focus on energy efficiency and the attention to the environmental impacts. Long time experience skilled people work together in synergic team with young generation technician in order to offer a wide range in design, manufacture and supply of different furnaces types for production of containers, tableware, lighting ware and technical glassware. FORMING BDF Industries glass container forming product line is the historical core business. BDF Industries is able to provide a wide range of machineries with a high level of production flexibility to meet the customers requirements. With more than 65 years experience in glass forming field, BDF Industries can offer the complete range of IS machine including gob forming and delivery, ware handling, container and variable equipment. The glass forming machineries are fully designed and assembled in house by BDF Industries in Italy, which has relevant knowledge of production process of the most important glass manufacturers in the world (e.g. strong credentials for forming business in O-I, Saverglass, Sisecam, Vetropack, Vitro...) Our R&D office is focused to find the best solutions applied into IS machines in order to match lower production costs for our Customers thanks to higher reliability and maintainability of our product. We continue to work towards research and innovations that will deliver genuine advantages in productivity and efficiency for our customers glass factories located in different area around the world. AUTOMATION The automation team involved in the Glass Industries focuseds its activity in the engineering process and software, during reconditioning and retrofitting of all part of Glass Factory including: plant designing, installation and startup, network configuration, control, staff training, customer service and remote assistance. The experienced, qualified, passionate and customer-focused staff is there to add value for customers, partners and suppliers. As part of its own philosophy, the team believes and operates in the sustainable development: the application of its carefully designed and implemented systems greatly save energy and relevant impact on the environment, thus improving the quality of life and the safety of the operators in the field as well as adding economic and social value to the community. A fundamental key of success in the automatic control is the interlink with melting and forming teams which makes the final product completely fit with the Glass Factory requirements. ENERGY The large BDF Industries experience in the glass industry and automation makes us the more qualified counterpart when it comes to improve, re-qualify or reinvent a glass production plant. To master the challenges of global competition, our customers must minimize costs, continually increase the productivity of their systems and meet ever-stricter environmental regulations. Our innovative and ecofriendly solutions help to conserve natural resources, improve energy and capital utilization and optimize processes. For our customers, this means lower raw materials consumption, fewer emissions, greater energy efficiency, lower costs and increased output. The experience into demanding environment as the glass industry is our key point to succeed around you. We can all make a difference. By applying different type of technologies, BDF Industries is able to supply a full package of energy recovering and/or renewable energy systems. Resources from waste: heat recovery system of waste gases to produce electric energy via ORC turbine or steam turbine. Waste gases treatment: dust filtration and waste gases chemical compounds abatement techniques. These are some package solution examples of what BDF Industries can offer, develop, deliver and install. SERVICE The reliable and innovative partner for running glass making plants to maximize productivity, quality, reliability, maintain assets and contain costs. BDF Industries has a Service organization dedicated to provide a complete spectrum of the highest quality service solutions to satisfy the needs of our clients from a single source. Our services support the entire product value chain from melting glass making to forming, filtering, energy facilities and automation. The service product line includes installation & startup, upgrades of mechanical equipment and automation, technical assistance for repairing and overhauling, training, performance evaluation & long term service agreement, integrated maintenance management & diagnostic solutions and systems, spare parts. The contents of service are the following: Supply local qualified supervisors Supply of certified end/or upgraded OEM (Original Equipment Manufacturer) spare parts for all maintenance operations Performance of all equipment maintenance Repairs using state-of-the-art technology Optimization of Spare Parts inventory On the job Training of local maintenance and operation personnel The BDF Industries service team supports the strategic goals of glass factory by stimulating growth in core skills and providing personalized programs for the glass industry. The BDF Industries Learning Center in Italy and strategically located Service Centers offer a wide range of programs in technical courses. Our technical courses are presented by field-tested experts combining understanding of theory and practical experience. The quality training provided is a prerequisite to improve the skills of operating and maintenance personnel, so as to assure knowledge, safety and higher equipment availability. 4 ENERGY ON GLASS ENERGY ON GLASS 5

4 GLASS CATALOGUES CONDITIONING WORKING END FOREHEARTH MELTING FURNACE ENERGY ON GLASS GATALOGUE INDUSTRIAL AUTOMATION CATALOGUE FORMING IS MACHINE FORMING DELIVERY WARE HANDLING INDEX ENERGY ENTHALPY RECOVERY PAG 8 ENVIRONMENTAL PROTECTION PAG 12 EMISSION MONITORING PAG 14 6 ENERGY ON GLASS ENERGY ON GLASS 7

5 ENTHALPY RECOVERY ENERGY TOWER CONCEPT WITH LOW FOOT PRINT IMPACT SUITABLE FOR GLASS MANUFACTURING PLANT BDF ENERGY No interference with the furnace processes Important annual energy savings Electricity production Small Installation area required Quick payback is possible No media high pressure involved in the process Well known technology 20 years lifetime technology BDF technology is fully suitable and tested for glass manufacturing plant BDF patented system to prevent heat exchanger from fouling Possible integration with other BDF Industries products BATCH CHARGER FURNACE DEDUSTING MIX BOX HEAT EXCHANGER ORC TURBINE DeSOx FILTER DeNOx CEMS LFP (LOW FOOT PRINT) BDF has developed this Energy tower concept to reduced the required installation area for the glass plant. COMPRESSED AIR PRODUCTION It is possible for BDF to generate compressed air with the same plant. This could be useful for payback reason in some countries. 8 ENERGY ON GLASS ENERGY ON GLASS 9

6 ENTHALPY RECOVERY ENTHALPY RECOVERY HOT WATER PRODUCTION THIS IS BDF BASIC SOLUTION FOR ENTHALPY RECOVERY. HEAT EXCHANGER COULD EASY GENERATE AN HIGH AMOUNT OF STEAM OF HOT WATER. Short payback time, high efficiency. Some uses for this hot water/steam are: Office heating District heating Sanitary water Food industry usage Cullet washing Steam industrial usage FUMES COOLING SYSTEM GLASS FURNACE HEAT EXCHANGER CEMS HOT WATER CHILLED WATER PRODUCTION BY USING ABSORPTION UNIT IS POSSIBLE TO EXPLOIT THE HEAT IN THE FUMES TO PRODUCE CHILLED WATER. Absorption unit technology can determines the chilled water temperature, 4-5 C for Br-Li or 0 C from ammonia based absorption unit. The chilled water can be used for: Air conditioning Food industry Store temperature control Cooling for IS cooling system Br-Li absorption unit need heat exchanger and evaporating tower installation to operate. COGENERATION TRIGENERATION OPTION BDF CAN OFFERS THE COMBINATION BETWEEN ELECTRICITY GENERATION, HOT WATER AND CHILLED WATER PRODUCTION. IN THIS WAY IS POSSIBLE TO BOOST THE PAYBACK. USING ELECTRICITY, STEAM AND CHILLED WATER PRODUCED IN YOUR OWN PLANT CAN REDUCE MOREOVER THE PAYBACK TIME. FOR THESE REASONS THE BIGGER INVESTMENT IN INSTALLATION COSTS COULD BRING TO A SHORTER PAYBACK THAN A NORMAL ENERGY TOWER SOLUTION. Other option that BDF engineering can offer are: Distillation unit to produce distilled water exploiting the heat in the fumes. Seawater cooling system that can produce bags of salt ready for selling. 10 ENERGY ON GLASS ENERGY ON GLASS 11

7 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION FILTRATION - DEDUSTING BAG FILTERS SLEEVES Basic principle is to select a fabric membrane which is permeable to gas but retain the dust. Initially dust is deposited both on the surface fibers and within the depth of the fabric, but as the surface layer builds up, it itself become the dominating filter medium. This cake of dust increase also the resistance to gas flow, so periodic cleaning of the filter are mandatory to prevent the pressure drops. HIGH TEMPERATURE FILTER MEDIA CERAMIC CANDLES Same principles of bag filter but the filter material is ceramic (or stone wool in some cases) that can resist to higher temperatures: this device is called candle. Further technologies combine NOx removal by the embedding of catalyst in this ceramic candles. MAIN GLASS PLANT POLLUTANTS O O N N N O O O N O Nitrogen Oxides - NOx S O O O O S O Sulfur Oxides - SOx H Cl Chlorides - HCl H F Fluorides - HF NOx AND SOx BDF SYSTEM ABATEMENT ECOLOGIC GLASS PLANT SLEEVE CERAMIC CANDLE Dust efficiency removal Very high Capture metals High also with high dust loading, but low with small particles Possible re-use of collected dust Yes Collected in dry conditions Yes Collected in dry conditions Pressure drop High if not cleaned Moderate Reaction to moisture Bad Good Temperature of Exercise Max 220 C Over 500 C Energy use Low, unless high pressure drops Low, unless high pressure drops Investment cost Safety issue Size Re-heating for DeNOx None Small Yes difficult explosion relief for flammable materials Small No POLLUTANTS ABATMENT, NOx AND SOx ABATEMENT SELECTED CATALYTIC REDUCTION SCR SELECTED NON-CATALYTIC REDUCTION SNCR DRY OR SEMI-DRY SCRUBBER HYDRATED LIME Involves reacting NOx with ammonia(nh3) or urea(ch4n2o) in a catalytic bed at the appropriate temperature. According with temperature windows there are several catalysts available. The most common are vanadium and titanium oxides(tio2 and V2O5) embedded in ceramic or metallic substrate, or zeolites. The catalyst units are modular honeycomb structures. The operating temperature of the system are usually from 200 C to 500 C with the optimum between 300 C and 450 C. Also known as thermal DeNOx, the oxides of nitrogen in the waste gases are reduced by reaction with ammonia or urea. The chemical reactions are the same of SCR system but take place at higher temperatures without the need for a catalyst. The operating temperature is in the range C and the optimum is around 950 C for ammonia and 1000 C for urea. For this reason in SNCR the reagent injection is closer to the furnace than SCR. 1-2 seconds are required to obtain a good efficiency from the reaction. An absorbent reagent is introduced and dispersed in the waste gas stream. this material reacts with SOx (but also metals and acid species HF and HCl) to form a solid, which has to be removed by a filtration system. Is possible to inject the reagent directly in the fumes ducting or in a reaction tower or chamber for a more efficient process. This absorbent reagent is a powder (usually Ca(OH)2, NaHCO3, or Na2CO3)for dry scrubber, or a water solution of NaCO3 or Ca(OH)2 for semidry scrubber. In the glass industry the most common is the dry application that use Ca(OH)2 namely hydrated lime. Flue gas volume (Nm 3 /h) High Temperature Technology CERAMIC CANDLE Low Temperature Technology FABRIC SLEEVE C1 S C2 S C3 S C4 S C5 S C6 S6 FILTRATION PROPOSED FILTER SIZE According to heat exchanger models we can find 12 different filers that can be used with the same volume of the waste gasses. 12 ENERGY ON GLASS ENERGY ON GLASS 13

8 ENVIRONMENTAL EMISSION MONITORING BDF CEMS 87 Devices for extractive and in-situ emission measurement Measuring technologies (e.g. NDIR, UV, electrochemical or paramagnetic principle, filter correlation, scattering light) Single and multi-component analyzers, on customer request Certified system by government agency CEMS system can be integrated in plant control scada system Low maintenance costs Possible integration with process control. Possible supervision integration with other glass plant controls. Possible installation at ground level (fast-loop option). BDF CEMS 87 IN-SITU BDF CEMS 87 FAST LOOP 14 ENERGY ON GLASS

9 BRANCHES REPRESENTATIVES WHERE BDF INDUSTRIES IS ACTIVE BDF INDUSTRIES S.p.A. Headquarter Viale dell Industria, Vicenza - Italy phone BDF SHANGHAI Trading Co., Ltd. Room 1301/2, 818 Nanjing West Road, Shanghai - China phone BDF INDUSTRIES North America LLC 800 Town and Country Boulevard - Suite Houston - Texas phone BDF SERVIS D.O.O. Hum Na Sutli 107/4, Hum Na Sutli Croatia phone (0) /16 - studiobrand.it In order to ensure a continuous improvement of the products, BDF Industries reserves the right to make modifications to the characteristics and pictures (without notice) BDF ALL IN ONE MELTING FURNACE CONDITIONING WORKING END FOREHEARTH FORMING DELIVERY FORMING IS MACHINE WARE HANDLING ENERGY ON GLASS INDUSTRIAL AUTOMATION