TEKNOLOGIST INSTITUT Århus Oktober 2008

EnerDry ApS

Arne Sloth Jensen

Tørring af roepulp og andreprodukter I overhedet damp.

TEKNOLOGIST INSTITUTÅrhus

Oktober 2008

EnerDry ApS

1. Udvikling af damptørringsteknikken.2. Hvordan virker tørreren. 3. Kapaciteter3. Næsten 100% energibesparelse 4. Pulp som brændstof5. Miljø6. Forøget produktion7. Udviklingen i USA.8. Damptørring i Europa.9. Økonomi10. Tørring af andre produkter. 11. Energibesparelse og reduktion af CO2 emission. 12. Konklusion.

EnerDry ApSEnerDry ApS

EnerDry ApS

EnerDry ApS

3,5 bar SteamHeat

Wet pulp

Dry pulp

EnerDry ApS

Udvikling af damptørringsteknologien

• 1979 De første ideer• 1981 Oliekrise, Start af

udviklingsarbejdet. • 1983 Pilotanlæg• 1985 Prototype i Stege, • 1990 Secheur installé en Nangis, France• 2008 21 anlæg i drift + 1 under bygning.


Box 6'' x 6''for up to5 bar

Window

Cell fordrying smallsamplesin steam. Superheated

steam

Steam from topalso possible.


Pressurecontrol

Product out

Product in

Flow control

Boiler5 bar

Electricsuper-heater

EnerDry ApS

Installation pilot en construction1983

EnerDry ApS

l’Installation pilot 1983

EnerDry ApS

L’Installation pilot de debut.

EnerDry ApS

L’Installation pilot modifiée

EnerDry ApS

Prototype 1985

EnerDry ApS

Prototype

EnerDry ApSLe sécheur. Sucrerie de Nangis

EnerDry ApS

EnerDry ApS

Steam in and out

Boiler steam 139171 lb/h(400 psig)

Steam to evaporator 111111 lb/h

Pure flash steam to evap. 28333 lb/h

Returned total 139444 lb/h

EnerDry ApS

Energy suppliedSupplied heat

Steam for heating 52801 kW(53119 kW -318 kW)

Condensate out 18079 kW

34722 kW

Supplied power 1220 kW

Which is roughly the double of a drum dryer with same capacity

.evaplbBtu1076=lb110229

kWh34722

= 2501 kJ/(kg evap)

EnerDry ApS

Energy consumption

0

200

400

600

800

1000

1200

1400

1600Bt

u/lb

eva

p.

Drum Dryer Steam Dryer

Returned energy

Used energy 19 Btu/lb evap

Supplied energy1076 Btu/lb evap

Supplied and used energy1400 Btu/lb evap

EnerDry ApS

Indpasning i eksisterende sukkerfabrik.

• Aldrig ændringer I kedelhuset. • El-produktionen bliver ofte ændret.• Det første trin i fordampeapparatet må være delt

i 2 parallelle trin.

EnerDry ApS

122.5

45.2

Pulp 3.4 Pulp 1

0.6

Loss

121.1

Loss20.4

167.6

DrumDryer

Boiler28 barg

300ºC

Turbine

Evaporators

18.5 31.3

18.5

1

89

80.8

31.8

80.8

89.8

21 t/h

Tota

l93.

6

Energy flow in a factory with drum drying of pulp.10 000 ton beets / dayMW energy flow

0.5

EnerDry ApS

Steam Dryer

115.3 115.1

19

52.6

Loss 0.1

Loss19.2

59.9

2.6

53.9

2.6

48.3

11.2

7.8

2

86

53.9

48.3

Boiler28 barg

300ºF

Turbine

Energy flow in a factory with steam drying of pulp.

10 000 ton beets / day

MW energy flow

Evaporators

Pulp 3.4 Pulp 1

1.2

23 t/h

Tota

l93.

6

EnerDry ApS

Hvordan kan brændstofforbruget i kedelhuset blive reduceret.

• El-produktionen er reduceret. .

• Strømforbruget til tørreren genvindes.

• Energien i den 50oC varme pulp bliver løftet op til niveauet for damp til fordampeapparatet.

EnerDry ApS

Beet pulp as fuel

The power production is based on:10 000 t beets per day.All pulp is burned in the boiler. Boilers produce 85 bar steam at 525°C.Boiler efficiency 88%Isentropic efficiency of turbine 85%Efficiency of gear and generator 95%The condenser temp is as high as 60°C. Lower condenser temperature could increase the power production.

EnerDry ApS

Evironmental improvements.

Tørringen finder sted I et lukket system. Derforer der ingen emmission til atmosfæren. .

* Intet Støv* Ingen VOC (lugt)* Ingen CO2

EnerDry ApS

Intet støv til atmosfæren.

Men dampen fra tørreren har 2ppm småpartikler, som ender som suspended stof i kondensatet.

EnerDry ApS

Ingen VOC(ingen Volatile Organic Components).

Ingen lugt.Det er et lukket system, men der er nogle ikke kondenserbare gasser.Denne udluftning indeholder nogle organiske syrer og andre VOC. Varmen i denne skal udnyttes, hvorved disse stoffer går over i vandfasen. (kondensatet)Den resterende emission kan på denne måde bringes ned under 25 gC/h fra 50 t/h vandfordampning.

EnerDry ApS

Vandfasen forøger BOD belastningenpå sukkerfabrikken spildevand med

ca. 2%

EnerDry ApS

Tabt produktion fra forbrænding.

EnerDry ApS

Steam dried beet pulp vs. Drum dried beet pulp

EnerDry ApS

Loss of product by burning in drumdriers.

EnerDry ApS

Steamdryers in USA

50 t/hEnerDry 2007Size HMNAmerican CrystalSugar

East Grand Forks

38 t/h50 t/hEnerDry 2006Size HMIMichiganBay City

73 t/h71 t/hEnerDry 2006Size JIDAmalgamatedNampa

40 t/h50 t/hEnerDry 2003Size HNDMinn-Dak Farmers

2 x 40 t/h2 x 40 t/hNiro 1999. Rebuildt by EnerDry 2004

2 x size 10MNSMBCS

Usedcapacity

Nominel capacity

SupplierDryerStateCompagny

EnerDry ApS

Piping around steam dryer Nampa

EnerDry ApS

Steamsystem at Nampa sugar factory

SteamSystem Nampa

EnerDry ApS

*Calculated based on operation data. Not tested due to steam system and lack of pulp

83 t/h31 t/h114 t/h14/28 barCalculatedmax

Capacity*

73 t/h27 t/h100 t/h13,5/24,8 bar

Avarage 24h 14 Febr.

2007

71 t/h28/28 barGuarantee

67t/h14/28 barGuarantee

EvapPulp outPulp inSteamsupply

EnerDry ApS

• Steam dryer reduces potential for power production.• Split 200/400 super heater gives less power reduction

• 2006/07 Reduced power production 4 MW• 2007/08 Future reduced power production 2.5 MW• Saved fuel 62.0 MW

• The saved fuel could make 30 MW power in a modern power plant.

EnerDry ApS

EnerDry ApS

Pulp Dryer Stacks BeforeSteam Drying Operation

EnerDry ApS

Pulp Dryer Stacks AfterSteam Dryer Operation

EnerDry ApS

Steamdryer at Bay City, Michigan

EnerDry ApS

The steamdryer at Minn-Dak Farmers, North Dakota

EnerDry ApS

Damptørring af roepulp i Europe.

Der er 10 damptørrere I drift I Europa for tiden. Heraf 6 i i Østtyskland, hvor alt det pulp der tørres, bliver tørret i overhedet damp under tryk. De to ældste står i Frankrig. De blev sat i drift i 1990 og 1992. De fleste øvrige blev bygget i 90’erne

EnerDry ApS

Ny interesse for damptørring i Europa

1) Stor stigning i energipriserne.2) Krav om reduceret støvemmision.3) Reduktion af CO2 emission.4) Kommende krav om reduceret lugt og

reduceret VOC emission.5) Efter at EU sukkerordningen er faldet påplads begynder investeringerne så småt igen.

EnerDry ApS

Energibehov i dag.I Vesteuropa har der været en god udvikling i energibehovet over de sidste 30 år – fra ca 250 kWh/tom roer til 170kWh/t roer i selve fabrikken.I dag 170 kWh/ton beet. Tromletørring af pulp 90 kWh/ton beet.Total 260 kWh/ton beet.

Der findes en fabrik der damptørrer 75% af pulpen og laver al den strøm som fabrikken har behov for. Den bruger kun 157 kWh/t pr ton roer. (Målt gennemsnit for en uge).

EnerDry ApS

EconomyMinn-Dak Farmers.Max 50 t/h evaporation2003; 9.3 mill $ = 6 mill. €for the total project

Amalgamated Sugar Co.Nampa Factory. 2006; Max 83 t/h evaporation. 16,5 mill $=10,6 mill €for the total product.

EnerDry ApS

EconomyIn Europe a 50 t/h (Size H) project could cost like this:

Investment:Dryer ex works 4,3 mill €

Transport and erection 1.2 mill €

Evaporator 1,0 mill €

Building 1,2 mill €

Piping and conveyors 1,8 mill €

Varoious 1,0 mill €

Total 10,5 mill €

EnerDry ApS

EconomyYearly profit from steamdrying.

Gain per year.Saving on gas:45000x3000/3600/1000=37,5 MW37,5x29x24x100= 2,61 mill €

No pulp burnt1,5x100x24 180= 0,65 mill €

Saving on labor andMaintenance. 0,20 mill €

Total 3,46 mill €

Lost power production -0,25 mill €

Net gain per 3,21 mill €100 day campaign

The numbers arebased on:Assumed 45t/h evaporation out of max 50 t/h

Gas: 29 €/MWh

Losses in the alternative drum 6% = 1,5 t/h pellets. 180 €/ton pellets.

Reduced power production 3 MW; 70 € per MWh.

EnerDry ApS

Why dry wet Solid Fuels?

• Burning wet fuel use primary energy to evaporate H2O

• The water vapor takes up volume in boiler and the exhaust gas cleaning system, reducing the capacity.

• Wet fuel give more pollution

EnerDry ApS

Wood chips for district heating

With steam drying and power production

Power produced: 34,5 MWeDistrict heat: 117,4 MW

EnerDry ApS

Steamdrying of other products. 2 steamdryers for wood chips and bark in Sweden.

EnerDry ApS

Våde brændsler, som bør damptørres.

• Træflis• Bark• Bagasse• Brunkul

EnerDry ApS

Tørret slam fra aerob vandrensningsanlæg

EnerDry ApS

Damptørring og Ethanol

Ethanol fremstilling i USA på basis af især majs er vokset voldsomt de sidste år. Det er et par hundrede fabrikker.

Restproduktet tørres i tromler til DDGS.

One dryer in USA has been tested for drying of DDGS from ethanolproduction. And a lot of lab tests has been made.

By steamdrying the fuel consumption can be reduced 9200 to 5300 kJ per liter ethanol.

En anden slags ethanol er ølbrygning. Masken vil også være et velegnet produkt for damptørring.

EnerDry ApS

Lucernetørring.

Tidligere var tromletørring af lucerne meget udbredt, da olieprisen var lav.

Damptørring af lucerne er også muligt med stor energibesparelse til følge.

Der kræves en vis præparation af lucernen, hvis den er meget våd.

Her et par eksempler på systemer.

EnerDry ApS

67,5 t/h Boiler feed water134°C10540 kW

18399 kW

50,4 t/h, 3,0 bar, 145 °C, 2750 kJ/kg, 38500 kW

Boiler

Gas fired43 barMax 90 t/h

AIR

Alfalfa 20% DS116 t/h

Predied Alfalfa30,5 % DS,76 t/h

Dryed Alfalfa90 % DS25,8 t/h

40 t/h evap.

50 t/h evap.

Size J

30°C126 kJ/kg1764 kW

44595 kW1,11 MWh/ton evap.959 kcal/kg evap.

Energy from boiler house.43512 kW0,48 MWh/ton evaporated415 kcal/kg evaporated.

EnerDry ApS

71,1 t/h54411 kW

Boilerhouse

Gas fired43 bar

AIR

Pulp 28% DS28 t/h

Dried pulp8,7 t/h90%DS

Pulp feed28% DS 102,6 t/h

19.3 t/h evap.SizeJ

28950 kW1,5 MWh/ton evap.1290 kcal/kg evap.

70,7 t/h evap.

71 t/h

94208 kg/h28 bar, 250°C2865 kJ/kg74974 kW

16972 kg/h4625 kW

76836 kg/h20938 kW

77236 kg/h70349 kW


Heat from Vacuumpan vapour


Gas consumption in boiler house does not increase comparedto the factory operation today. The vapour from the pan-boiling is “free”. Therefore is the heat consumption:0 MWh/ton evaporated =0 kcal/kg evaporated.

The power production will be reduced. A rough estimate ofthis reduction is:9 MW if the steam compression is maintained.3 MW if the evaporation is modified to 6 steps. Further more will the two driers consume more power than theold installation.

EnerDry ApS

Boiler 1Gas fired43 barMax 90 t/h

Boiler 2Gas fired43 barMax 90 t/h

74 t/h

0 t/h

73 t/h

23 t/h

0 t/h

13 t/h

43 t/h

0 t/h

159 t/h

0 t/h

36 t/h

5,4 MW

EnerDry ApS2 size H driers. 2 x 40 t/h evap. Steamdrying and partly 5½ step evaporator. 10 MW powerprod. Low condenser loss.

91 t/h

80 t/h

80 t/h

1 t/h tocondenser

1A+B+C

0 New 4000 m2

543

91 t/h Boiler feedwater50 bar, 208 °C Directly into boiler

9 t/h 100 t/h

3,7 bar a

2

4,6 MW

19bar a

2 sizeH

EnerDry ApS

6792 t CO2reduction per year per invested mill €

Investment:10.6 mill €

No raw material used

72000 t CO2reduction per year

200 ton coal per day not fired.

600 t/day CO2emission avoided.

In 120 days per year

Nampa Steam dryer

EnerDry ApS



Investment: 200 mill €Investment:10.6 mill €

2200 ton/day wheat is used.700 ton/day DDGS produced


119000 t CO2 reduction per year72000 t CO2reduction per year

Production 8000 hl/day.Avoided CO2 emission 1200 t/dayCO2 from cultivation: -250 t/dayCO2 from boilers: -600 t/dayNet CO2 reduction: 350 t/day

In 340 days a year.




An ethanol factory on wheatNampa Steam dryer

EnerDry ApS




Investment: 12 mill €Investment: 200 mill €Investment:10.6 mill €

No raw material used2200 ton/day wheat is used.700 ton/day DDGS produced


13000 t CO2 reduction per year119000 t CO2 reduction per year72000 t CO2

reduction per year

Average production:23% = 1,8 MW. A coal fired power plant will need 3,8 MW as fuel corresponding to 500 kg coal per hour. Avoided CO2: 36 t/day. In 365 days a year.

Production 8000 hl/day.Avoided CO2 emission 1200 t/dayCO2 from cultivation: -250 t/dayCO2 from boilers: -600 t/dayNet CO2 reduction: 350 t/day

In 340 days a year.




4 x 2 MW windmillsAn ethanol factory on wheatNampa Steam dryer

EnerDry ApS

Conclusion

• Up to 83 ton/h water evaporation in one drier.

• 6 large steam dryers in operation in USA. • 100% saving of fuel for drum drying is

theoretical possible.• Zero emission of dust, VOC or smell. • More reduction of CO2 emission then by

other investments.

TEKNOLOGIST INSTITUT Århus Oktober 2008

Documents

Transcript of TEKNOLOGIST INSTITUT Århus Oktober 2008