1 ERA.NET RUS PLUS: Optimization of industrial steam networks in order to raise the electricity yield in Russian enterprises Consortium partners: Energy Efficiency Center of Nizhni Novgorod Allplan GmbH, Vienna Munich University of Applied Sciences
2 ERA.NET RUS PLUS InitiativeThe project is carried out under framework of the ERA.NET RUS PLUS Initiative. The initiative aims to support and encourage technological innovation and knowledge transfer between the EU Member States and Russia. The funding parties involved in this specific project are: Foundation for Assistance to Small Innovative Enterprises (FASIE) Austrian Research Promotion Agency (FFG) DLR Project Management Agency Simulation of steam networks
3 Consortium Partners The project is a cooperation project between three partners from Russia (lead), Austria and Germany: Energy Efficiency Center of Nizhni Novgorod (Russia) Allplan GmbH (Austria) Munich University of Applied Sciences (Germany) Simulation of steam networks
4 ALLPLAN GmbH BUSINESS FIELDS Planning HVAC Building PhysicsEnergy and Environment Energy efficiency and energy audits in process and buildings International consultants: EBRD, World Bank, UNIDO, KfW Verification consultants Energy efficiency trainers Research and development Simulation of steam networks
5 Research and Development ProjectsALLPLAN GmbH Research and Development Projects Different projects concerning innovation in energy efficiency Demand response potential in Austrian industrial and commercial sector: balance of fluctuation in energy networks due to increase of renewable energy share SolBau: Cost-effective use of component activation as energy storage for increasing the energy efficiency of residential buildings Transform to LowEx: Decrease of medium temperature in district heating networks for buildings Industrial steam network optimization to increase the electricity output Simulation of steam networks
6 Previous Project ExperienceIndustrial steam network optimization to increase the electricity output The project was developed by ALLPLAN in cooperation with international paper companies Mondi Sappi Mayr-Melnhof Karton ALLPLAN carried out an analysis of the steam networks and through a static simulation of different scenarios selected the best measures to be implemented in order to increase the electricity output Simulation of steam networks
7 Previous Project ExperienceIndustrial steam network optimization to increase the electricity output Methodology Simulation of steam networks
8 Previous Project Experience Implemented measures and resultsMeasure 1: installation of a small electric steam generator Electricity production increased approx. 100 kW Payback time of investmet approx. 3 years Simulation of steam networks
9 Previous Project Experience Implemented measures and resultsMeasure 2: installation of a thermo compressor Back pressure decrease approx. 0.4 bar Electricity production increased approx. 400 kW Payback time of investment approximately 0.7 years Simulation of steam networks
10 Previous Project Experience Implemented measures and resultsMeasure 3: direct usage of steam from other steam boilers Electricity production increased approx. 400kW Payback time of investmet approx. 2 years Simulation of steam networks
11 Project objectives Increasing electricity production from steam turbines in Russian companies With optimisation measures with short pay back time Considering: Differences in ambient temperatures summer / winter Dynamic production process Simulation of steam networks
12 Automotive industry 18,000 475 85 14 Students Professors Degree programmes (Bachelor's and Master's) Departments Biotechnology & life sciences Design & media Energy technology Finance Health/social sciences IT & communications We are based in a leading European business hub. With this size and location come significant opportunities and responsibility in diverse industrial, economic, and social contexts. City of Munich info (http://www.muenchen.de/rathaus/wirtschaft/wirtschaftsstandort/kennzahlen) State capital of Bavaria Population of 1.5 million Largest concentration of DAX-listed companies in Germany Several global market leaders Highest share of highly skilled workers in Germany (35%) Large proportion of graduates stay in the region Strong international community: 25% foreign nationals, consular posts Renowned venue for trade fairs and conferences Strong startup culture Safety and excellent quality of living (one of the world's best cities to live in; awarded 7th place in 2015 Mercer ranking) "Munich's economic strength stems from its broad-based economic structure, a balanced mix of large corporations, small and medium enterprises, and craft businesses in a wide range of sectors." (City of Munich info) Aerospace engineering Tourism Business services
13 Department of Mechanical, Automotive and Aeronautical EngineeringLargest Department of Technology at the University of Applied Sciences Munich Around 2,200 students About 300 graduates per year Around 70 professors and about 80 part-time lecturers from industry 80 research, laboratory and administrative staff (8 in the Strascheg Center for Entrepreneurship) Simulation of steam networks
14 Laboratory for Energy and Process EngineeringThermodynamics Turbo machinery Power engineering Thermal and mechanical process engineering Conversion of waste heat into electricity Rapid prototyping for CFK structural components Head of Laboratory Association: Prof. Dr Erwin Zauner Simulation of steam networks
15 Simulation tasks at MUASSetup of simulation models of the energy supply systems at different industrial sites Calibration of the models based on measured operational data Simulation results which allow to analyse the power losses, the critical components and the influence of ambient conditions Development of optimisation measures in cooperation with the project partners Simulation of steam networks
16 Example of an industrial steam networkPlant output: - electric power - process steam and heat at different levels 6 bar 12 bar 3 bar Simulation of steam networks
17 Typical losses in steam networksTurbines: efficiency: 70 – 90 % Piping: press. loss: < 1bar temp. loss: < 5°C Control valves: press. loss: up to 5 bars or even more Back pressure turbine with extraction [Source: Alstom] Piping system of a power plant [Source: Siemens] Control valve of a steam turbine [Source: Siemens] Simulation of steam networks
18 Losses– an example Pressure loss in pipes or valvesExpansion in a turbine 6 bar 200°C 1 kg/s steam 6 bar 200°C 85% effic. 1 kg/s steam 4 bar 195°C 4 bar 163°C Power output: 0 kW Power output: 69 kW Simulation of steam networks
19 Simulation method Software applications are used to simulate energy and power plant systems in order to engineer, design and optimise processes The models are created by arranging predefined compo-nents and pipe connections Components and pipes require several input parameters Apparatus 6 Pump 6 Simulation of steam networks
20 Simulation tool EBSILON®Professional is widely established at universities, manufacturers and operators of plants Model of a steam power plant [Source: STEAG] Simulation of steam networks
21 Simulation results - basicFor defined operating points: Overall results for power, heat, exergy, etc. Detailled information on pressure, temperature, enthalpy, exergy, etc. at any position in the system Example results Energy output: Electric power: kW Heat and steam: kW Exergy: Input: kW Electric power: kW Heat and steam: kW Turbine losses: kW Pipe losses: 110 kW Valve losses: 110 kW Simulation of steam networks
22 Simulation results – optimisationAs an example a frequently encountered situation in existing networks is considered: The steam turbine back pressure is higher than necessary Possible reasons: requirements have changed since installation but no readjustment has been taken place safety margins are too high no dynamic adjustment according to ambient conditions is carried out (winter/summer) steam/heat consumers who only need small amounts of steam at increased pressure (see next slide) Simulation of steam networks
23 Simulation results – optimisationSteam demands of the plant: 5 kg/s at 12 bar (HP) (example) 1 kg/s at 6 bar (IP) 9 kg/s at 4 bar (LP) Replacement of control valve by steam compressor HP IP LP Big losses Increase in power output: 510 kW or 3570 MWh (7000 h/a) Simulation of steam networks
24 Simulation results - optimisationParameter study with steam compressor: High power increase can be achieved at small IP-mass flows and low LP-levels Only back pressure reduction Simulation of steam networks
25 Simulation results - optimisationBenefits of steam compressors: Power increase since LP steam is fully expanded in LP-turbine Retrofit opportunity for existing plants No moving parts: simple and reliable Steam compressor [Source: TLV] Simulation of steam networks
26 Dynamic simulation resultsEBSILON®Professional can perform time series simulation to take into account dynamic changes in operating and ambient conditions Simulation of steam networks
27 Necessary information and input dataThe configuration of the steam network Design data of components Measurements of operating data Project team supports data gathering on site Simulation of steam networks
28 Expected results and outlookreduction of losses dynamic optimised back pressure increased electricity production up to 5% reduced energy costs up to several 100k€ pay back times of less than 3 years In a maximum of 3 industrial companies in Russia Simulation of steam networks
29 Contact details Evgeniy Zenyutich [email protected] (Russian)Tel: +7(831) Helmut Berger (English & Russian) Tel: Erwin Zauner (English) Tel: Simulation of steam networks