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  • 2013 Energy Presentation

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    quamie
    38 vues29 pages
    The document presents production and energy consumption data for Windalco Ewarton Works from January to October 2013. It shows trends in hydrate production, fuel oil consumption for boilers and calcination, total energy usage, and energy costs. Opportunities for improvement through heat recovery from live steam heaters are also discussed, which could save an estimated 7 tons of fuel oil per day.

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    Energy Presentation

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    The document presents production and energy consumption data for Windalco Ewarton Works from January to October 2013. It shows trends in hydrate production, fuel oil consumption for boilers and calcination, total energy usage, and energy costs. Opportunities for improvement through heat recovery from live steam heaters are also discussed, which could save an estimated 7 tons of fuel oil per day.

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    © All Rights Reserved
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    38 vues29 pages

    2013 Energy Presentation

    Transféré par

    quamie
    The document presents production and energy consumption data for Windalco Ewarton Works from January to October 2013. It shows trends in hydrate production, fuel oil consumption for boilers and calcination, total energy usage, and energy costs. Opportunities for improvement through heat recovery from live steam heaters are also discussed, which could save an estimated 7 tons of fuel oil per day.

    Droits d'auteur :

    © All Rights Reserved
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    sur 29

    Windalco Ewarton

    Works

    Energy

    Quamie Mortley PhD


    Energy Update 2013
    2013 Production
    1,800
    1,700
    1,600
    1,500
    Production

    1,400
    (t/d)

    1,300 Hydrate
    1,200 Alumina

    1,100
    1,000
    900
    800
    Jan Feb Mar Apr May Jun Jul Aug Sep Oct
    Total HFO Consumption
    700
    643
    593 587
    600 546 567 553 562
    514 527
    500
    500
    HFO (t/d)

    400

    300

    200

    100

    0
    Jan Feb Mar Apr May June Jul Aug Sep Oct
    Boiler Fuel Oil Consumption
    (t/d)
    500
    457
    450 432 420 427
    401 408
    400 385 388
    369 362
    350
    300
    HFO (t/d)

    250
    200
    150
    100
    50
    0
    Jan Feb Mar Apr May Jun Jul Aug Sep Oct
    Boiler Fuel Oil Consumption
    (t/t Hydrate)
    0.350

    0.300 0.277 0.287


    0.257 0.256 0.247 0.249 0.258 0.258 0.251
    0.250 0.230
    HFO (t/t)

    0.200

    0.150

    0.100

    0.050

    0.000
    Jan Feb Mar Apr May Jun Jul Aug Sep Oct
    Calcination Fuel Oil Consumption
    (t/d)
    200 186
    184
    180
    164
    160 155 155
    145 143
    135 138
    140 127
    120
    HFO (t/d)

    100
    80
    60
    40
    20
    0
    Jan Feb Mar Apr May Jun Jul Aug Sep Oct
    Calcination Fuel Oil Consumption
    (t/t Alumina)
    0.13

    0.11 0.110
    0.10 0.102 0.102 0.104 0.103 0.102
    0.096 0.098 0.097
    HFO (t/t Alumina)

    0.09

    0.07

    0.05

    0.03

    0.01
    Jan Feb Mar Apr May Jun Jul Aug Sep Oct
    Total Energy Consumption
    (GJ/t)
    18.0

    17.0
    16.2 16.1
    16.0
    15.2 15.2 15.1 15.3
    15.0
    14.3
    Energy

    14.0 13.8
    14.0 13.6

    13.0

    12.0

    11.0

    10.0
    Jan Feb Mar Apr May Jun Jul Aug Sep Oct
    Powerhouse Energy Consumption
    (GJ/t)
    13.0
    12.1
    12.0 11.7

    10.8 11.0 10.9


    Energy

    11.0 10.7 10.5


    10.4 10.5

    10.0 9.7

    9.0

    8.0
    Jan Feb Mar Apr May Jun Jul Aug Sep Oct
    Calcination Energy Consumption
    (GJ/t)
    4.5

    4.4 4.34 4.35 4.32


    4.3 4.24 4.23
    4.23
    4.2 4.13
    4.1 4.07
    4.04 4.03
    Energy

    3.9

    3.8

    3.7

    3.6

    3.5
    Jan Feb Mar Apr May Jun Jul Aug Sep Oct
    Energy Cost
    250 Energy Cost Fuel Oil Price Poly. (Fuel Oil Price) Fuel Oil Price 610
    231 215 232 ($/t)
    220 217 225 218
    203 202 205 600
    200
    590
    Energy Cost ($/t)

    150
    580

    570
    100

    560
    50
    550

    587 586 602 606 587 569 567 569 568 574
    0 540
    Jan Feb Mar Apr May June Jul Aug Sep Oct
    Fuel Oil Price
    ($/t)
    610 606
    602
    600

    590 587 586 587


    HFO ($/t)

    580
    574
    569 567 569 568
    570

    560

    550

    540
    Jan Feb Mar Apr May June Jul Aug Sep Oct
    Powerhouse
    Configuration
    Steam Distribution
    Boiler 1 Boiler 2 Boiler 3 Boiler 4

    600# Header
    JPS

    600/100# PRV 600/35# PRV

    TG1 TG2 TG3 BFWP #1

    100# Header
    Turbine Leakoff
    Turbine Leakoff
    Process
    100# Steam

    35# Header

    Process 35# Steam Powerhouse 35# Steam


    TG1 Condenser
    Powerhouse Hot-Well
    Steam
    (t/h)
    262
    260 250
    240 238 238 241
    240 235
    224
    217
    220 211
    Steam (t/h)

    200
    180
    160
    140
    120
    100
    Jan Feb Mar Apr May June Jul Aug Sep Oct
    Powerhouse Design Model
    Powerhouse Reconfiguration Model
    Opportunities For
    Improvement
    Heat Recovery - Live Steam Heaters
    • Heater condensate level control, reduced
    condensate temperature, higher heat transfer

    • Steam reduction of 5 t/h

    • Oil savings 7 t/d

    • Savings $1,500,000 per year


    Available Condensate (t/h)
    Stream Maximum Available @
    Available 1800 t/d
    Digester 1 (Live Steam) 40 32
    Digester 2 (Live Steam) 40 32
    Evaporator 1 (Live Steam) 20 18
    Evaporator 2 (Live Steam) 20 20
    Evaporator 3 (Live Steam) 22 22
    Caustic Cleaning Heater (Live Steam) 5 5
    Tube Heater (Live Steam) 13 13
    IBSH (Live Steam) 12 8
    ECU (Live Steam) 10 10
    Ball Mill Heater (Live Steam) 6 0
    Evaporator 3 Regenerative 85 63
    7A Flash Tank Regenerative 25 22
    7C Flash Tank Regenerative 25 22
    TOTAL 323 267
    Additional Condensate Recovery (t/h)
    • Additional Regenerative Condensate to be
    recovered
    Stream Maximum 1800
    Available t/d

    Digester 1 Regenerative 45 38

    Digester 2 Regenerative 45 42

    Evaporator 1 Regenerative 60 60

    Evaporator 2 Regenerative 60 50

    TOTAL 210 190


    Potential Savings From Additional
    Regenerative Condensate Recovery

    • Heat Value in Condensate

    • Reduced Boiler Blowdown (increased boiler


    cycles)
    Additional Condensate Savings
    • Regenerative Condensate Phase 2 (install tank
    and pump)

    • Recover additional 70 t/h

    • Savings $2,300,000/Y
    Powerhouse Efficiency
    Improvement
    Powerhouse Efficiency Improvement
    • The Powerhouse Boiler Efficiency is Shown.

    • Improved Steam Economy.


    Boiler Evaporation Efficiency
    (t steam/t oil)
    16.0
    14.9 14.7
    15.0
    14.1 14.0 14.1
    14.0 13.7 13.8 13.8
    13.5 13.3
    13.0
    Steam (t/h)

    12.0

    11.0

    10.0

    9.0

    8.0
    Jan Feb Mar Apr May June Jul Aug Sep Oct
    Boiler Efficiency Improvement
    Milestones
    • April 2013 MaxHT on both Digesters and all
    Evaporators

    • May 2013 Digester Regeneration Condensate


    recovery for BFW
    THANK YOU FOR YOUR
    ATTENTION

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