Boilers and cogeneration/trigeneration Abhi Sawant Business Development Manager Simons Green Energy
HEATING - COOLING - SUSTAINABLE ENERGY ENERGY EFFICIENCY IN BOILERS, COGENERATION & TRIGENERATION Presented By
Simons has been a leader in Thermal Energy for over 80 years 1932 1940 s 1950 1960 s 1970 1980 s 1980 2000 Foundation Manufacturer for the army during the WWII Steam irons Air compressors Electric & gas burners Expanded range of electric boilers for Food manufacturers & Hospitals Export of a full range of boilers to Europe and South East Asia New range of steam and hot water products. 2013 2012 2011 2010 Cogeneration Absorption Chiller Trigeneration Cogeneration Cogeneration Foundation
Boilers and Cogeneration Boilers High Efficiency Standard Efficiency Gas Fired Cogeneration Systems 4kWe 2,680kWe Absorption Chillers 100kWr 6,950kWr
Steam & Hot Water Boilers STEAM BOILERS Electric and Gas Create Steam for the following applications: Process Heat in manufacturing Cooking in Food processors Apiarists Hospitals & Universities Pharmaceutical Industry Hotels HOT WATER BOILERS High & Std Efficiency Boilers Create Hot Water for process heating and air conditioning applications in the following applications: Industrial Process Heating Food Processing Hospitals & Universities Shopping Centres Commercial & Government buildings
Existing Boilers in Manufacturing Facilities ISSUES & CONSIDERATIONS Key items that can affect the efficiency of a boiler The age of the boiler Steam condensate not being fed back into the boiler and hence wasted into drain less efficient Lagging/ Insulation missing or damaged Steam traps leaking or missing Leaking pipes Leaking valves Lack of Boiler Maintenance
Existing Boilers in Manufacturing Facilities How to optimise the efficiency of a boiler? Regular maintenance of a boiler is key to make sure the boiler runs with the highest efficiency A Boiler is like an old car if you have not looked after it, it will not run as well as if you had maintained it properly
Replacing Boilers CONSIDERATIONS When should the boiler be replaced? If the boiler is leaking, has scale build up or debris inside. A boiler older than 5 years that has not been properly maintained A boiler older than 20 years that has been properly maintained What s new in boiler technology for manufacturers Condensing hot water boilers more efficient Modulating burners are more efficient and burn less gas. Energy efficiency Standard boilers are 80% efficient compared to the 96% efficiency of condensing boilers
New Boilers Case Study New Boiler Installed: 350 kw Gas fired steam boiler Issue An electric steam boiler that was not properly designed and installed and it was not well maintained. Application Steam is being used for a testing chamber where they test train carriage & coach air conditioning systems under different atmospheric conditions
What s new in Boilers CONDENSING HOT WATER BOILERS High Efficiency pre mix condensing boiler up to 96%. Environmentally friendly reduce up to 80% of NOx and 90% of CO Low gas consumption Product range: 85, 100, 120, 150 kw Indoor & outdoor floor standing boilers Modular Units
Cogeneration & Trigeneration for Energy Efficiency Key Energy Issues Definitions of Cogeneration & Trigeneration? Where do they fit in manufacturing processes? Focus on Cogeneration and how it works? Focus on Trigeneration and how it works? What determines if they are suitable for you? Drivers : Cheaper Cleaner Electricity with free Heating or cooling
Key Energy Issues Reduce Carbon Emissions Avoid Sharp Electricity Price Rises Implement Sustainable and Secure Energy Policies
Electricity Costs Source: IPART
Cogeneration 4kWe 2,680kWe DEFINITIONS Cogeneration Combined Heat and Power (CHP) is the simultaneous production of electricity and heat using a single fuel such as natural gas Trigeneration Combined Heat, Power and Cooling (CHPC) is the simultaneous production of electricity, heat and cooling using a single fuel such as natural gas
Why Co/Trigen for Manufacturers? Large and consistent electrical loads Suitable load range typically from 50kWe to 2100kWe Multiple uses for waste heat from engine Hot Water Steam Chilled Water for Cooling, Refrigeration & Air Con
Solutions for Manufacturers? Cogeneration Hot Water Supply Cooking Wash down Process Heat Steam Supply Steam Jacketed Pans Ovens Sterilisation Process Heat Where does it fit? Trigeneration Air Conditioning For office & production areas Chilled Water For process requirements Refrigeration Of stored and finished products
Key factors to determine suitability Spread between fuel and electricity prices Electrical load profile Simultaneous & consistent demand for electrical and thermal energies over long operating hours Fuel availability Adequate space Compatible with existing equipment Cooperative energy authorities for grid connection Achievable exhaust gas emissions Acceptable noise profile
Cogeneration How does it work?
Trigeneration Trigeneration goes one step further Combined Heat, Power and Cooling (CHPC) is the simultaneous production of electricity, heat & cooling using a single fuel.
Cogeneration Skid Mounted - Bare
Cogeneration Skid Mounted Acoustic enclosure 50kWe 500kWe
Cogeneration Containerised 30ft or 40ft container Three chambers for generator, controls & oil 600kWe 2,000kWe
Cogeneration Cogeneration modes of operation o GRID PARALLEL MODE o ISLAND MODE
Absorption Chillers for Trigeneration Single and Multi Energy - Capacities: 100kWr 6,950kWr
Trigeneration Rejected heat 25ºC 35 ºC Heat Absorption Chiller Chilled Water 90ºC 200 ºC Down to 5 C C.O.P. = Cooling Output (kw) Heat Input (kw) (Coefficient of Performance) o Single effect absorption COP 0.7 o Double effect absorption chiller COP 1.2 o Conventional electric chillers COP 3.0 6.0 o Dependent on method and efficiency of heat rejection
Operation Specifics Hot Water up to 96 C Chilled Water down to 5 C Typical size range 100kWe 6,000kWe Continuous operation covering multiple shifts Up to 25 year service life Possible back up power supply during grid failure
Drivers of Co/Trigeneration for Energy Efficiency Reduce Energy Costs (currently up to 20% of exp.) Reduce Carbon Footprint Generous Government Incentives Part of overall Energy Efficiency Strategy Improve Corporate Image
The Key is - Cheaper and cleaner electricity from natural gas with free heating & cooling
Little Creatures Brewery Case Study
Design Factors Connection mode System output electrical/thermal Operating hours Integration Sizing Correct Sizing Wrong Sizing P+ S and Trigen Supply with chiller offset 1000 900 peak + shoulder Trigen supply P+S-chiller offset P+ S and Trigen Supply with chiller offset 1000 900 peak + shoulder Trigen supply P+S-chiller offset 800 800 700 700 600 600 kw 500 kw 500 400 400 300 300 200 200 100 100 0 0 2000 4000 6000 8000 10000 12000 0 0 2000 4000 6000 8000 10000 12000
Little Creatures Brewery Geelong Requirements Improve energy efficiency 96 C hot water produced by the Cogeneration System will reduced the amount of steam needed from the site s traditional boilers Hot water will be stored in massive water storage tanks and used for numerous process heating applications Reduce carbon footprint Reduce costs Ensure reliable supply of electricity and heat Avoid disruption to operations during installation
Little Creatures Installation
Little Creatures Installation ISSUES Daily electrical load distribution at site & corresponding sizing of the Cogeneration System. Space availability & access to site. Permitted noise levels. Type of connectivity.
Little Creatures Technical Summary Capable of generating up to 10,000MWh of electricity and 11,000Mwh of thermal energy per annum Significant energy cost reductions Massive reduction in CO2 emissions 4.5 years estimated payback period Improved Corporate Environmental Image 85% electrical conversion efficiency versus 30% of grid power
Financial Analysis Typical Investment metrics Payback ~4 years + IRR up to 40% per annum Strong positive NPV Operating Costs / Savings Fuel, consumables, maintenance costs, overhaul allocation Electricity & gas avoided, future price Capital Expenditure System costs, enabling works, structural works, installation Typical capital investment ~$500k $2m increases, export to tenants, carbon price benefit, social/community benefits Useful economic life ~25 years
THANK YOU Contact: Abhi Sawant Email: Abhi@simonsgreenenergy.com.au P. 03 9462 6700 F. 03 9462 6711 755 Botany Road Rosebery NSW 2018 www.simonsgreenenergy.com.au