A QUANTUM LEAP The biggest change in energy efficiency since the shift from steam to diesel propulsion machinery

Transcription

1 A QUANTUM LEAP The biggest change in energy efficiency since the shift from steam to diesel propulsion machinery Jon Åge Eidem, Ulmatec ULMATEC Ulmatec Handling Systems AS, Ulmatec Components AS, Ulmatec Skipsservice AS, Ulmatec Pyro AS, Ulmatec Engineering AS, Ulmatec Baro AS, Penetrators Norge AS, Penetrator Inc. Ulmatec Asia Pte Ltd Ulmatec Well Products As, Powder Tec AS, Ulmatec Services LLC Ulmatec Baro LLC Hareid, Norway Hareid, Norway Fosnavåg, Bergen, Tromsø, Norway Gamlem, Norway Hareid, Norway Fosnavåg, Norway Stavanger-Ulsteinvik, Norway Canada, North America Singapore Stavanger, Norway Surnadal, Norway Dubai, UAE Houston, North America 4 1

2 MORE THAN 60 YEARS OF KNOW-HOW Pyro founder Palmar Bjørnøy Cold trips to Shetland MORE THAN SHIPS WORLDWIDE WITH PYRO HEATING SYSTEMS 6 2

3 ÅRETS BEDRIFT MØRE OG ROMSDAL 2014 ÅRETS NYSKAPAR NORDVESTLANDET Our focus and promise since 2011 recovering otherwise wasted energy instead of using highgrade energy in the form of oil or gas 8 3

4 In 2011 we claimed ONLY 30-40% OF ENERGY IS USED EFFICIENTLY 60%OF ENERGY CAN EASILY BE UTILISED 9 Now, in 2015, we know that CAN BE UTILISED 10 4

5 PYRO WASTE ENERGY MANAGEMENT SYSTEM A QUANTUM LEAP The most important energy saving invention since moving from steam engine to diesel engine Steam engine % efficiency / utilisation Diesel engine % efficiency / utilisation Diesel Engine + Waste Heat Recovery 2011* % efficiency / utilisation Diesel Engine + Waste Energy Management 2015** % efficiency / utilisation * In 2011 Ulmatec Pyro introduced the Pyro Waste Heat Recovery System ** In 2015 Ulmatec Pyro introduced the Pyro Waste Energy Management System 11 RUN YOUR HEATING, COOLING AND POWER SYSTEMS AT MINIMUM COST We see a great many opportunities for huge savings by transferring energy consumption from electricity to waterborne heat even generating electric power from waste heat recovery 12 5

6 MADE POSSIBLE WITH PYRO SYSTEMS Traditional products Fuel Fired Heater Exhaust gas Economiser Incinerator System New products Waste Energy Recovery System (patent) Tank Heating System (patent) 13 MADE POSSIBLE WITH... GREEN TECHNOLOGY from ULMATEC, SPERRE & ANDA OLSEN SPERRE Pleat & Rack Coolers with their uniqe competence and low pressure drop. ANDA OLSEN battery technology for energy storage and peak operations together with CLIMEON New products De-Icing System (patent) Ballast Water Management System (patent) Waste Energy Cooling System (patent) Waste Energy Power Generation System (patent) Waste Energy Management System (patent) 14 6

7 UNDERSTANDING THE ENERGY CONVERSION Rated power Heat rejection to coolant Heat rejection to exhaust gas Heat rejection to charge air aftercooler Heat rejection to air from engine Heat rejection to air from generator Total effect Caterpillar 3516C (data from engine supplier) kw ,6 % ,2 % ,3 % 59,7 % ,2 % 161 2,4 % 91 1,3 % ,0 % Fuel consumption Engine load Engine load Engine load Fuel energy Fuel energy KJ/s (kw) Max. Specific Fuel value KJ/kg L/h kg/h kg/kwh 100 % ,16 0, % ,60 0, % ,92 0,256 kw Load % Energy Cost NOx kg/year Effekct Energy/24h Consumption Nox Fuel Cost kw kwh kg/kwh *3) kg/kg *1) USD/kg *2) USD/literkg/liter KJ/kg NOx tax USD Fuel USD Total USD Engine < 200 rpm (Generator) ,256 0,1000 2,40 0, Engine rpm (Generator) ,256 0,0530 2,40 0,60 0, Engine rpm (Generator) ,256 0,0500 2,40 0,60 0, Engine >1500 rpm (Generator) ,256 0,0440 2,40 0,60 0, Fuel fired heater (MGO) ,091 0,0036 2,40 0,60 0, Heat recovery *1)= kg Nox / kg fuel Engines ( kW og >1500kW) before year 2000, Nox value increase 0,001 kg/kg *2)= USD/ kg. Nox (19,19NOK/8,00USD/NOK=2,40 USD/kg) *3)= Engine speciffic values to be used (e.g g/kwh) *4)= Spesiffic density MGO 0,86 kg/liter 15 FUEL SAVINGS Offshore Vessel 120mx22m Engine Installation 5xCaterpillar 3516C kw Average Engine load 2x50% 2500 Available Waste Energy 100% engine load 3200 kw Actual available Waste Energy 50% engine load 1250 kw Crew 120 Ballast Water capasity 5000 m3 Installed cooling effect kw Operational hours 8760 h Energy efficiency 0,256 kg/kwh Desity fuel 0,86 kg/liter Avearage consumption/year Tropical Area Northern Area Artic Area Effect kw Energy kwh Effect kw Energy kwh Effect kw Energy kwh Heating of accomodation Cooling of accomodation Fresh Water Production Sanitary Hot Water Tank Heating Tank Washing De-Icing Ballast Water Treatment Pre-heating of engine at standstill Total waste energy used Fuel Fired Energy Available waste energy Electricity production 10% efficiency , Fuel savings (Liter) Total Fuel Consumption (Liter) Total Fuel Saving 19 % 26 % 30 % 16 7

8 Example of benefits = 2000 LITRE Marine gas oil price is going up and down. Currently the cost is about US$500 per tonne and has been up to US$ 960 per tonne, but is expected to increase tous$1,800 by 2020, and to US$2,300 by 2035 REDUCED PUMP EFFECT FUEL/YEAR Source: Article by Chad Henderson, Wallenius Wilhelmsen Logistics, October Adjusted for current prices (September 2015). 17 PYRO WASTE ENERGY COOLING SYSTEM Fixed rpm Frequency controlled Frequency controlled Fixed rpm 18 8

9 PYRO WASTE ENERGY COOLING SYSTEM FUEL SAVING: kwh = LITRE FUEL/YEAR Example Cooling effect: Pump capacity: Pumping effect: Energy Consump. 2 pumps: Traditional kw 4x800m3/h 4x100 kw kWh WECS kw 6x400m3/h 6x50 kw kWh 19 PLATE HEAT EXCHANGER (PHE) SPERRE PLEAT COOLER 240 MAN-HOURS 1 MAN-HOUR 45 GASKETS 50 DAYS OFFHIRE 1 GASKET 1 DAYS OFFHIRE 9

10 Energy saving solution Fuel savings - Emission reductions Reduced energy consumption on the seawater-pumps due to low pressure drop Rack cooler have no marine growth due to CuNi 90/10 and antifouling paint Chilled water element reduces running time at the chilled-water compressors Heat recovery element makes it possible to use the surplus heat PYRO WASTE ENERGY COOLING SYSTEM 4 = LITRE Four pumps with automatic regulated valves which only pumps the required volume and flow of cooling water. Reduced number of pumps saves energy. A flexible system that works. REDUCED PUMP EFFECT FUEL/YEAR Fixed rpm 22 10

11 PYRO COOLING SYSTEM BENEFITS Reduced no. of cooling pumps installed Reduced no. of cooling pumps running Full control of cooling temperatures Reduced no. of heat exchangers installed Full control of circulation pressure Possible to utilize the waste low temperature (LT) cooling energy Full flexibility in no. of cooling pump running (automatic start/stop) Less energy used for cooling water circulation Monitoring the waste energy utilized - and wasted to sea and air (exhaust) 23 PYRO WASTE ENERGY MANAGEMENT SYSTEM CASE STUDY INSTALLATION 140m Offshore Construction Vessel DP3-4 split power system No. of seawater (SW) cooling pumps reduced from 30 to 12 reduction = 18 No. of freshwater (FW) cooling pumps reduced from 26 to 12 reduction = 14 No. of seawater heat exchangers reduced from 20 to 8 reduction = 12 No. of freshwater heat exchangers increase from 0 to 4 increase = 4 A minimum of cooling pumps running according to cooling requirement In DP mode: 2-8 SW cooling pumps FW cooling pumps running Normal mode: 1-8 SW cooling pumps FW cooling pumps running Full flexibility and back-up capacity DNV GL verified solution Significant reduction in engineering time Significant reduction in installation time Standardised and modulated plug and play units 24 11

12 PYRO WASTE ENERGY POWER GENERATION SYSTEM EGB HT circuit 85C-95C EMISSION-FREE ELECTRICITY Cooling water 0C 35C Product range from 150kWe to 600kWe 25 PYRO WASTE ENERGY POWER GENERATION SYSTEM 1300kW WASTE ENERGY ELECTRIC POWER 26 12

13 ANDA PRODUCTS AC UPS systems DC UPS systems Power supplies Chargers Inverters Batteries System solutions Motors & drives Hybrid systems Converters 13

14 WASTE ENERGY POWER GENERATION SYSTEM BENEFITS Converting engine waste heat to electricity (jacket cooling and exhaust) World record efficiency, twice as high as competing technologies Up to 5% fuel savings per annum Significant emission reductions Attractive payback times despite low oil prices Marine proven Remote diagnostics with Live 29 Smart, flexible and cost effective PYRO -WASTE ENERGY MANAGEMENT SYSTEM 30 14

15 WEMS WASTE ENERGY MANAGEMENT SYSTEM WERS - WASTE ENERGY RECOVERY SYSTEM WECS - WASTE ENERGY COOLING SYSTEM WEPG - WASTE ENERGY POWER GENERATION B B B A B B HEAT COMSUMERS Air handling units Fresh water generators Tank heating system Tank washing system De-icing Ballast water treatment Electric power generation B UNITS TO BE COOLED Engine high temp cooling Engine low temp cooling Thrusters Provision plant Electric equipment Chill water Propulsion motor / gear Hydraulic equipment COMPONENTS 1 Fuel Fired Heater 2 Exhaust Gas Economiser 3 Split valves 4 Flow control units 5 High temp heat recovery heat exchanger 6 Fresh water cooling pumps 7 Sea water / fresh water heat exchangers 8 Sea water cooling pumps 9 Expansion tank 10 Circulation pumps A B A 31 SUMMARY ENERGY UTILISATION Utilized in engine 35% Waste energy from exhaust system 12% Waste energy from HT cooling system 13% Waste energy from LT cooling system 10% Utilised in Climeon system 5% TOTAL 32 15

16 QUESTIONS TO OUR BRAVE CLAIM? A QUANTUM LEAP The biggest change in energy efficiency since the shift from steam to diesel propulsion machinery Jon Åge Eidem, Ulmatec 16