ANGUIL. we will begin shortly. Take the Heat and Reuse it Oxidizer Operating Cost Reduction Strategies

Transcription

1 Take the Heat and Reuse it Oxidizer Operating Cost Reduction Strategies AIMCAL Fall Technical Conference 2009 Presenter: Jeff Kudronowicz / Application Engineering Manager at Anguil Sponsored By: ANGUIL Thank you for joining us, we will begin shortly.

2 As a thank you for attending We would like to offer you a free, 30 minute consultation. Please call or Kevin Summ at (414) / kevin.summ@anguil.com Or Stop by our table top display to discuss your application questions. ANGUIL Milwaukee, Wisconsin Phone: (414)

3 Company Background Founded in 1978 Family owned and operated Headquartered in Milwaukee, WI with additional offices across the world Industrial Air Pollution Control and Energy Recovery Systems Deb,Gene and Chris Anguil

4 Presentation Overview: Oxidizer System Optimization Identifying Opportunities Strategies & Options Case Studies Question and Answer

5 Motivation: Why Now? Rising Utility Costs Tighter Emission Regulations Stimulus & Grant Money Availability Media Coverage Media Coverage (Marketing Bonus)

6 Identifying Opportunities Zone Approach: - Zone A: Upstream of Oxidizer - Zone B: Internal to Oxidizer - Zone C: Oxidizer Exhaust Stack Consider the ways in which Oxidizer Systems use energy in each of these Zones

7 Identifying Opportunities Zone A: Upstream of Oxidizer There is a Design Volume of Process Exhaust Air that must be: Captured (Horse Power Cost) Delivered to Oxidizer (HP Cost, Heat Loss Cost) Sometimes Filtered (HP Cost) Sometimes Pre Heated (Heat Input)

8 Identifying Opportunities Zone A: Upstream of Oxidizer Must be replaced in the Process with Process Conditioned Air Must be replaced in the Plant with Plant Conditioned Air

9 Identifying Opportunities Zone B: Internal to Oxidizer Regenerative Thermal Oxidizers Catalytic Oxidizers Thermal Recuperative Oxidizers

10 Identifying Opportunities Zone B: Internal to Oxidizer Heat Inputs: Heat Input for Main Process Airflow Heat Input for Combustion Airflow Heat Input for Purge/Puff/Seal Airflow

11 Identifying Opportunities Zone B: Internal to Oxidizer Additional Energy Usages: Fan HP (System, Combustion, Purge) Outer Skin Heat Loss to Atmosphere Controls, Compressors, Hydraulics

12 Identifying Opportunities Zone C: Oxidizer Exhaust Stack Energy that cannot be safely, reliably, or costeffectively retained in the oxidizer system itself is released to the atmosphere

13 Identifying Opportunities Sometimes helpful to think of Oxidizer as a simple, "black box system

14 Identifying Opportunities Simplified Model does not consider: Radiant and Convective Heat Loss Moisture Content in Solvent Laden Airstream (SLA) Heating Value of Chosen Fuel at Chosen Operating Temperature VOC Loading Profile Electrical Operating Costs

15 Optimization Strategies Zone A: Upstream of Oxidizer Reduce Airflow Increase VOC Concentration Reduce the Oxidizer Workload!

16 Optimization Strategies Zone A: Upstream of Oxidizer Reduce Airflow through: Re-establish proper balance (Follow up with training i and indicators) Traditional a methods: tighter te capture, recirculation, cascading V i bl h t th d P t l Variable exhaust methods: Pressure control, LEL Control

17 Optimization Strategies Zone A: Upstream of Oxidizer Special Case: Permanent Total Enclosures (PTEs) Permit Compliance may demand that a fixed amount of air is exhausted at all times PTE Air is typically high volume, low concentration, ti near room temperature t

18 Optimization Strategies Zone A: Upstream of Oxidizer VOC Concentrators Large Flow / Low Concentration Airstream Small Flow / High Concentration Airstream Concentrators Reduce the Oxidizer Size!

19 Optimization Strategies Zone A: Upstream of Oxidizer Concentrator Applicability: Airflows > 5,000 SCFM (7,900 Nm³/h). Inlet Temperature < 100ºF (40ºC) VOC Concentrations < 500 ppmv. DRE < 99% Relative Humidity < 90% The higher the VOC boiling point, the better it adsorbs and the harder it is to desorb Must be a liquid at room temperature in order to adsorb

20 Optimization Strategies Zone B: Internal to Oxidizer

21 Optimization Strategies Zone B: Internal to Oxidizer Primary Heat Recovery: Hot, purified air leaving the retention chamber is used to pre-heat the incoming Solvent Laden Air (SLA).

22 Optimization Strategies Zone B: Internal to Oxidizer Increasing Oxidizer Primary Heat Recovery Adding high-efficiency ceramic media to a Regenerative Thermal Oxidizer Replacing the hottest pass of the Shell-and-Tube heat exchanger in a 40,000 SCFM Thermal Recuperative Oxidizer

23 Optimization Strategies Zone B: Internal to Oxidizer Focus on Combustion Air

24 Optimization Strategies Zone B: Internal to Oxidizer Focus on Combustion Air Consider Process Air as Combustion Air Consider Pre-Heating Combustion Air (By blending with stack air directly or through a stack HX) Reduce Combustion Air with Enhanced Firing Rate Controls Eliminate Combustion Air (for RTOs)

25 Eliminate Combustion Air SFI (Supplemental Fuel Injection) Also known as: NGI Natural a Gas Injection or Flameless Operation Custom Designed Injection Quill Additional Fuel Train Piping Why Use SFI? Reduces combustion air- flow, lowering operating costs Lower pilot rate for large burners Ultralow NOx emissions

26 Optimization Strategies Zone C: Oxidizer Exhaust Stack Even after optimizing in Zones A and B, sometimes significant ifi energy conservation opportunities remain in the oxidizer exhaust stack. CDE s ABC s of Stack Energy Recovery

27 Optimization Strategies Zone C: Oxidizer Exhaust Stack CDE s of Stack Energy Recovery Capturing p g Stack Heat Energy Delivering g that Energy Back into the Plant Cost-Effectively Employing the Recovered Energy Efficiently Inside the Plant

28 Capturing Stack Heat Heat Recovery Equipment Options: Air-to-Air Heat Exchangers Air-to-Fluid (Hot water/glycol Coils) Air-to-Steam (Waste Heat Boilers) Heat-to-Power (Cogeneration)

29 Air-to-Air, Plate Heat Exchangers Plate Style Heat Exchanger Heat Recovery 50-80% Applications: Low Particulate Process Streams Low to Medium Temperatures Pros/Cons: Cost per CFM LOWER than Shell & Tube Very Low Pressure Drop Temperature Limits of ~ 900F Max Based on Thermal Expansion and Materials of Construction

30 Air-to-Air, Shell & Tube Heat Exchangers Shell and Tube Heat Exchanger Heat Recovery: 50-70% Applications: High Particulate High Temperature or Corrosive Pros/Cons: Can be Made From High Alloy Materials for High Temperature and Highly Corrosive Applications Repairable in the Field, Robust, Pressure Test in the Field, Patch Individual Tubes Cost per CFM Higher than Plate Type

31 Air-to-Fluid Heat Exchangers Economizer Style Heat Exchanger Heat Recovery up to 50% Copper Tube / Alum. Fin Materials (Others Available) Applications: Low Particulate Process Streams 50 40, F to 1000 F Cost per CFM LOWER than Air-to-Air HX Very Low Gas Pressure Drop Numerous Applications

32 Air-to-Steam Heat Exchangers Waste Heat Boiler Heat Exchanger Heat Recovery up to 20% or More Utilize Energy From Stack to Generate or Preheat Boiler Feed Applications: Plant and Process Water Low Particulate Process Streams Medium Flow, High Temperatures Great Alternative to Heating Make-Up Water

33 Heat-to-Power / Cogeneration ORC (Organic Rankin Cycle) Power Generation up to 120 kw/hr Expander & Microturbine Types Pros/Cons: Emerging Technology Longer Pay-Back Great Alternative When Heat, Steam or Liquid are not Needed

34 Heat-to-Power / Cogeneration

35 Capturing Stack Heat Information Needed to Determine Project Feasibility: Expected Airflow & Average Temperature in the Oxidizer Stack Expected Hours of Operation Per Year Current Energy Rates (Gas or Oil and Electric) Other Considerations: Constituents in the Exhaust Stack System Fan Capacity

36 Delivering the Energy One Part Equipment Cost + Two Parts Installation Cost =Total Estimated Cost Mechanical and delectrical linstallation ti Exhaust Stack Modifications Controls Design, Supply and Interface System Integration Into Existing Processes System Startup and Balancing

37 Employing the Energy Practical Uses for Recovered Heat: Preheated eated Makeup Air for Process Ovens or Dryers Preheated Air or a Preheat Coil for Makeup Air Units Preheated Combustion Air for Process or Oxidizer Preheated Process Water or Boiler Feed water or Steam Plant Power Generation Optimize Payback by Employing the Energy in Processes Related to the Oxidizer!

38 Energy Efficiency Minimizes Greenhouse Gas Emissions

39 Oxidizer Optimization i Case Studies of Oxidizers Retrofit for Increased Energy Efficiency

40 Case 1: Improve Primary Heat Recovery ANGUIL Case 1: Improve Primary Heat Recovery % and Preheat Comb. Air

41 CASE 1: BEFORE

42 CASE 1: INTERMEDIATE APPROX SAVINGS: > $35,000.00/YEAR!

43 Added HX Module to increase Primary HX Efficiency

44 Added Duct System to Allow Blend of Stack Air with Combustion Air

45 CASE 1: AFTER APPROX SAVINGS: > $60,000.00/YEAR!

46 Typical Nozzle Mix Burner

47 Nozzle Mix Burner Exterior

48 Typical Inline Burner

49 Case 2: Improve Primary Heat Recovery %

50 CASE 2: BEFORE

51 Added HX Module to increase Primary HX Efficiency

52 CASE 2: AFTER APPROX SAVINGS: > $42,000.00/YEAR!

53 Case 2: Lesson Learned

54 ANGUIL Case 2: Burner Replaced

55 Case 3: Improve Primary Heat Recovery % in RTO

56 CASE 3: BEFORE

57 Added Heat Recovery Media to increase Primary HX Efficiency

58 CASE 3: AFTER APPROX SAVINGS: > $175,000.00/YEAR!

59 An RTO System rated for 95% Heat Recovery should typically show less than 100 F rise from inlet to stack.

60 Case 4: Eliminate Combustion Air with ANGUIL Case 4: Eliminate Combustion Air with SFI System in RTO

61 CASE 4: BEFORE

62 SFI = Supplemental Fuel Injection

63 SFI = Supplemental Fuel Injection

64 CASE 4: AFTER APPROX SAVINGS: > $45,000.00/YEAR!

65 Case 5: Secondary Heat Recovery at Discharge of Catalytic Oxidizer

66 12,000 SCFM 210 F CASE 5: BEFORE OXIDIZER 12,000 SCFM 475 F 9,000 SCFM HEATER 9,000 SCFM 350 F 70 F HEAT REQ D FOR OXIDIZER: HEAT REQ D FORHEATER: TOTAL HEAT REQUIRED: APPROX COST (3,000 hrs, $11): 3.45 MM BTU/hr 270MMBTU/hr MM BTU/hr $203,000.00/YEAR

67 Added d Secondary Heat Exchanger at Outlet of Catalytic Oxidizer

68 12,000 SCFM 210 F CASE 5: AFTER OXIDIZER 12,000 SCFM 275 F 9,000 SCFM HEATER 9,000 SCFM 350 F 300 F HEAT REQ D FOR OXIDIZER: HEAT REQ D FORHEATER: TOTAL HEAT REQUIRED: APPROX COST (3,000 hrs, $11): APPROX SAVINGS: 3.45 MM BTU/hr 050MMBTU/hr MM BTU/hr $130,350.00/YEAR > $70,000.00/YEAR!

69 ANGUIL Case 6: Reduce Airflow to RTO

70 CASE 6: BEFORE

71 CASE 6: AFTER APPROX SAVINGS: > $60,000.00/YEAR! /YEAR!

72 In Summary: 10 Tips 1. Know how much your oxidizer is supposed to be costing you to operate. 2. Pay attention to the percentages Especially primary TER (Thermal Energy Recovery) 3. Know your VOC emission profile Especially the amplitude and duration of peaks. 4. Know what oxidizer system would be specified for your process today. 5. Know what grant money is available to you for optimization projects.

73 In Summary: 10 Tips 6. Reduce exhaust airflow to oxidizer wherever possible. Consider concentration of high volume, low concentration and low temperature airstreams prior to oxidizer. 7. Focus on combustion air. Consider the source and temperature. Reduce, eliminate or pre-heat if possible. 8. Improve primary heat recovery when feasible. 9. Consider secondary heat recovery. 10. Properly maintain existing systems.

74 As a thank you for attending We would like to offer you a free, 30 minute consultation. Please call or Kevin Summ at (414) / kevin.summ@anguil.com Or Stop by our table top display to discuss your application questions. ANGUIL Milwaukee, Wisconsin Phone: (414)