THERMAL POWER PLANTS 28 th October, 2015 ATLAS COPCO INDIA - - PowerPoint PPT Presentation

ENERGY SAVING COMPRESSED AIR SOLUTIONS

THERMAL POWER PLANTS

28th October, 2015

ATLAS COPCO INDIA

• Established in the year 1960.
• Total employee strength : 1600
• Annual Sales

: ~ 22 BINR

• 4 Manufacturing plants
• Global Engineering Competence Centers at Pune & Bangalore
• Provide mechanical engineering, CAE, CFD, FEA and project engineering

support

• Annual Indian production 10,000 Screw compressors & 70 Centrifugal

compressors

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Energy Saving Energy Recovery

PRODUCT PORTFOLIO

HP Oil Free & Lubricated Piston MP Oil Injected Screw Oil Free Turbo Oil Free Screw LP Oil Free Screw Oil Free Turbo Compression Air Treatment Treatment Control & Monitoring Nitrogen Generation Generation

A CENTURY OF INNOVATION IN COMPRESSORS

1904

First oil- free piston

1952

First UR oil-free screw symetric profile

1973

First silenced compressors

1973

Scroll oil-free compressors

1979

Z tooth compressors

1980

Process turbo range

1980 1987

High pressure machines

1993

First full feature machines

1994

First VSD compressors

1995

Z integration

1966

First Z oil-free screw asymmetric profile

1970

MD energyless dryers

1964

First water cooled two stage piston

1954

First OIS

1995

First packaged and silenced turbo compressors

1996

Star insert coolers in Z

1997

High pressure 40 bar(e) machines

1986

Plant air turbo range

First Elektronikon control

….Over 400 patents

2001 2002

Double tooth introduction Z full feature with IMD

2003

First oil-free VSD

2003

AirScan introduced ZB high speed drives

2004 2005

AirOptimizer introduced

2006

Z screw gets ISO 8573 Class 0

XD energyless dryers

2005

Innovating the compressor business for more than 100 years

2010

Screw Blowers

OIL-FREE SCREW: Oil-free screw compressors & Blowers, fixed and variable speed 55 - 900 kW OIL-INJECTED SCREW: Oil-injected screw compressors, fixed and variable speed 2 - 500 kW CENTRIFUGAL: Standard Oil-free turbo compressors 350 – 3000 kW SCROLL: Oil-free scroll compressors 1 - 15 kW TOOTH: Oil-free tooth compressors 15 - 50 kW PISTON: Oil-free / Oil Injected Piston Compressors 0.5 - 10 kW

CORE TECHNOLOGY

Extensive product portfolio

SPECIFIC ENERGY J/l centrifugal screw tooth FLOW L/Sec

A rational mix of multiple technologies

CARING FOR ENERGY

scroll

INDUSTRIAL COMPRESSORS

Compressor Technique

Heatless purge Heat of compression Heated blower purge Heat of compression Twin tower Refrigerating

QUALITY AIR SOLUTIONS™

…….all types of dryers manufactured in-house

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WHY IS ENERGY IMPORTANT IN COMPRESSED AIR SYSTEMS ?

• Energy is up to 80% of a compressor’s lifecycle cost and 99% of its carbon footprint

Investment Maintenance installation

80% Energy

• From operating cost point of view : compressor room is one of the largest electricity user therefore is

priority equipment 15 to 20% of total Power Plant electrical consumption in Compressed Air System (CAS)

For a power plant of 800MW X 3, by reducing 5% in CAS Power Consumption Savings can be 500,000 KWH every year

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Typical Thermal Power Plant

Service Air 8 bar (real demand 5~6 bar) 100% Variable demand Oil Free Air Pneumatic Conveying Air Low presure Oil Free Air; No Air Dryer Stable demand of Ar required Instrument Air 8 bar (real demand 6~7 bar) 50% stable demand ; 50% Variable Oil Free Air ; - 40C ADP Flue gas desulphurization Low pressure Oil Free Air; No Air Dryer Stable demand of Air required Coal handling plants Dust suppression systems

ENERGY SAVINGS - AGENDA

Core Technology Drive Technology Efficient Air Treatment CAS Audit

Energy Savings

Optimization Energy Recovery Blower Technology

INEFFICIENT COMPRESSED AIR SYSTEM

• Main Improvement areas :

 Unwanted Blow-offs in centrifugal machines  Variable frequency drive in Screw Compressor  Energy Recovery  Twin Tower Adsorption dryers  Central control system  Low Pressure Blowers

Typical installation of compressed air system production

Turbo/Fixed Speed Turbo Turbo

Pre-filter Pre-filter Pre-filter Fine filter Fine filter Fine filter

Adsorption dryer Adsorption dryer

Adsorption dryer

Pressure Drop of 1.5 Bar

SER is to the tune of 0.192 KW / m3/hr

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Energy savings up to 25 % are possible !

• Heat of compression is used for drying
• No external energy or purge is required
• No filtration is required (no loose desiccant)
• Very low pressure drops

ENERGY SAVING DRYERS – MD DRYERS (Patented Technology)

Working principal

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100000 200000 300000 400000 500000 600000 700000 800000 900000 Heatless purge Heat regenerated (I)MD

Life Cycle Cost € 10 Year Dryer type

Maintenance cost Energy cost Delta compressor price Initial price

~ € 500,000 Savings (INR 35,000,000/-)

ENERGY SAVING DRYERS

Dryer Life Cycle Cost Comparison Based upon 1700 l/s (3600 CFM) of air, 8000 hrs per year, € 0.07/kWh (INR 5/- kWh)

15 - 18% Purge loss 2% Purge loss + Blower & Heater

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THE ENERGY RECOVERY SYSTEM

 the compression elements  the oil cooler  the intercooler  and the aftercooler

The unique built-in energy recovery system of the Atlas Copco Z compressor circulates water through all these components to maximize the potential heat recovery and yields hot water at up to 90°C. All energy used to compress air is transformed into heat, usually lost from the system.

Laws of thermodynamics

Recovers Energy up to 90%

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THE ENERGY RECOVERY SYSTEM

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ADVANCEMENT IN MULTIPLE COMP. CONTROL - ES

Multiple compressor installations are best controlled through a central controller This controller not only sequences the compressors and lowers the pressure band but has a possibility of starting and stopping different capacity machines to get the most efficient compressed air system

• Main innovative solutions:

 Hybrid Screw technology

• Oil-free Screw Fixed speed for the base load
• Oil-free Screw Variable speed for variable Load

 Heat-of-compression Dryers with 0 power & 0% losses  Energy Saving Central control system  Remote Monitoring through Smartlink  Energy Recovery system

ENERGY EFFICIENT INNOVATIVE SOLUTION

0% losses adsorption dryer 0% losses adsorption dryer 0% losses adsorption dryer

Oil-free Screw FS Oil-free Screw FS

Energy Recovery

Oil-free Screw FS Oil-free screw VSD

Central controller

MAXIMUM SAVINGS POSSIBLE

• Compressed Air usually represents 15% of a typical Thermal Power Plant’s electricity consumption
• Energy Savings possible for a 800MW X 3 plant every year :

– Installing Hybrid Screw compressors : Oil Free Screw FS + Oil Free Screw VSD : 10,87,500 KWH – Energy Recovery from Oil Free Screw compressors : 83,52,000 KWH – Central Controllers for optimum pressure generation : 3,88,000 KWH – Screw Blowers for ETP/WTP : 1,41,000 KWH – Air Leakage fixing : To be Assessed

Total Savings : 99,68,500 KWH per Year

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COMMITTED TO SUSTAINABLE PRODUCTIVITY.