Energy efficiency thanks to waste heat recovery: Siemens innovative concept for the glass industry
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1 Energy efficiency thanks to waste heat recovery: Siemens innovative concept for the glass industry Good reasons for invest in waste heat recovery Technical concept and typical system configuration Siemens portfolio for WHR plants References Scope of supply and financing offer
2 Good reasons for invest in waste heat recovery Savings Heating in winter and cooling in summer Increase of productivity Reduction of energy consumption costs Fast amortization within a few years (4 to 6 years based on electricity tariff) No additional personal required in control room Safety of investment Less dependency on external sources of energy Less dependency on constant rising energy costs Installation without influence on the production process Installation during line operation possible if bypass is available Use of standard components SIEMENS with strong experience in power plants Environmental protection Improvement of environmental protection Prevention of CO2 restrictions Gain in green image
3 Waste heat to electrical power Technical concept Furnace Glass Plant Waste heat recovery power plant Waste heat flow. Nm³/h Electricity supply. KWh
4 Working principle of an industrial waste heat recovery plant Plant electrical network
5 Typical technical concept and scope Waste Heat Flow from furnace(s) Boiler HP Flue Gas Cleaning System Boiler LP ID Fans (optional) Chimney (Natural Gas) Superheater Superheater G MV Cabinet MV Cabinet MV Cabinet MV Cabinet Boiler Feed Water System Condenser LV Cabinet LV Cabinet LV Cabinet LV Cabinet Civil Heating/Cooling Power Cooling System Electrical Power Flue Gas Flow Water Flow Steam Flow Siemens Scope existing
6 Waste Heat Recovery System with various options
7 Example of a multi-line concept: 2 glass lines with one turbo generator glass facilities 2 Boiler trains Turbo generator and control room Cooling towers Condensor
8 Industrial waste heat recovery solution Electrical power output for glass plants Example for a conventional float glass furnace: waste heat flow: Nm³/h temperature: 450 C electrical power output: 2 MW Example for two hollow glass furnaces (combination of the 2 waste gas flow on 1 boiler, see next slide / 2 lines concept, alternative 3) waste heat flow: Nm³/h Nm³/h temperature: 400 C electrical power output: 2 MW
9 Estimated electrical output depends mainly on Waste heat flow and furnace exit temperature Assumption: minimum T at basiss of stack = 180 C Inquiry data sheet for Waste Heat Recovery in the Glass industry waste heat flow (Nm3/h) MW 4,5 MW 4 MW 3,5 MW 3 MW 2,5 MW 2 MW 1,5 MW 1 MW 0,5 MW T exit furnace ( C) Feasibility study
10 WHR as integrated part of a glass plant Batch Warm area Cold End Batch Furnace Tin bath Annealing lehr Cutting line Preparing and mixing raw material Melting process 1560 o C Forming processs Cooling process Cutting WHR Utilities Further processing Waste heat recovery with water steam cycle Energy distribution, Compressed air, water,... Bending, grinding,.
11 Siemens portfolio for the glass manufacturing Application Process Batch Furnace Waste heat recovery Forming Cooling Cold end further processing Utilities MES-solution Plant Wide Automation solution Local operating / Monitoring Automation Field instrumentation Drives, Motion Control APC: Advanced Process Control SPC: Statistical Process Control Medium and Low voltage distribution incl. MCC Turbine and generator system
12 Automation architecture and energy distribution Operating System SIMATIC PCS 7 OS Client Automation System SIMATIC PCS 7 AS (redundant) Turbine and generator automation system Distributed I/O ET 200M Variable speed drive system SINAMICS Variable speed drive system SINAMICS 3000 kw P T F Steam turbine Generator SITRANS P, -T, -F Measurement: pressure, temperature, flow,... electro-pneumatic 1LA* position controllers Water pump, Valve control Condensate pump Cooling tower 1LA* Low voltage distribution and Motor Control Center with SIVACON 8P* energy distribution energy distribution and synchronization kw MV/LV
13 Automation architecture and energy distribution Operating System SIMATIC PCS 7 OS Client WHR application full integrated in Simatic PCS 7! Automation System SIMATIC PCS 7 AS (redundant) Turbine and generator automation system Distributed I/O ET 200M Variable speed drive system SINAMICS Variable speed drive system SINAMICS 3000 kw P T F Steam turbine Generator SITRANS P, -T, -F Measurement: pressure, temperature, flow,... electro-pneumatic 1LA* position controllers Water pump, Valve control Condensate pump Cooling tower 1LA* Low voltage distribution and Motor Control Center with SIVACON 8P* energy distribution energy distribution and synchronization kw MV/LV
14 Modular Equipment Steam turbine with generator Live Steam HP Turbine Extraction pressure regulated Project: Glass Factory Magdeburg TWIN-TURBINE LP Turbine Condensationssystem Steam Turbine Type: SST-110 (former TWIN CA 56) Start-up : 2009 Live Steam Pressure: bar Live steam temperature: C Intermediate Pressure: bar Exhaust Steam Pressure: bar Electrical Output: 3170 kwe
15 Waste Heat Recovery Boiler Total length (L) : Approx. 10m Total width (W) : Approx. 3,5m Total Height (H) : Approx. 3,5m
16 WHR plants in operation with SIEMENS products Germany Float Glass: Euroglas in Osterweddingen, 3 MW electrical power Float Glass: F-Glass in Osterweddingen, 2.5 MW electrical power Belarus Float Glass: Gomel, 3 MW electrical power
17 Waste heat recovery plant with 2.5 MW electrical power output f Glass, Germany, Float glass 700 t/day 60 % of electricity produced by furnace waste heat flow! * * CEO Dr. Ing. Wolfgang Räbiger in Glassfocus 2010
18 Thank you for your attention! Mail to : gs.india@siemens.com Internet:
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