optimisation of steam and condensate systems of paper machines

- The Environmental Managers -

Optimisation of Steam and Condensate Systems of Paper Machines

Energy Efficiency in IPPC Installations

Energy Efficiency in IPPC Installations G. Bachmann 2

- The Environmental Managers -

Dr. Gerald BachmannProject Manager Energy and EnvironmentALLPLAN GmbHSchwindgasse 10, A-1040 WienTelefon +43-1-505 37 07-43Telefax +43-1-505 37 07-27E-mail: gerald.bachmann@allplan.atwww.allplan.at

Energy Efficiency in IPPC Installations G. Bachmann 3

- The Environmental Managers -

Agenda

• Steam and Condensate Systems of Paper Machines• Optimisation Possibilities• Simulation• Experiments• Conclusion

Energy Efficiency in IPPC Installations G. Bachmann 4

- The Environmental Managers -

Steam and Condensate Systems of Paper Machines

Separator 1

Auxiliary Condenser

Separator 2 Separator 3

Heating Section 1

Hood Air Heating section

Heating Section 2 Heating Section 3

Separator 4

Energy Efficiency in IPPC Installations G. Bachmann 5

- The Environmental Managers -

Optimisation Possibilities

There are two main possibilities to identify better operating conditions

• Simulations• Experiments

1.Creating the simulation model

2.Feeding the model with data

3.Correct the model

4.Simulation

Energy Efficiency in IPPC Installations G. Bachmann 6

- The Environmental Managers -

Creating the simulation model

Simulation I

Energy Efficiency in IPPC Installations G. Bachmann 7

- The Environmental Managers -

Simulation II

Feeding the model with data

Correct the model

paper output [t/h]

coolant temperature [°C]

coolant flow [l/s]

water temperature [°C]

steam pressure HS 3 [bar]

steamconsumption[t/h]

steam pressureHS 5 [bar]

steam pressureHS 4 [bar]

steam pressureHS 3 [bar]

steam pressureHS 6 [bar]

steam pressureHS 2 [bar]

steam pressureHS 1 [bar]

Energy Efficiency in IPPC Installations G. Bachmann 8

- The Environmental Managers -

Simulation III

Correct simulation model

Energy Efficiency in IPPC Installations G. Bachmann 9

- The Environmental Managers -

Simulation IV

Energy Efficiency in IPPC Installations G. Bachmann 10

- The Environmental Managers -

Simulation V

• by partly separating the condensate the cooling water flow is reduced from 24t/h to 2t/h

• is not heating the cooling water anymore• the energy can be used at the level of 133°C• the power saving is about 3MW

Energy Efficiency in IPPC Installations G. Bachmann 11

- The Environmental Managers -

Experiments

• the experiments must not influence the production or the quality of the product

• during the experiments all parameters are observed at the process control system

Energy Efficiency in IPPC Installations G. Bachmann 12

- The Environmental Managers -

Conclusion

The results of the Simulation were confirmed by the experiments on the paper machine

power saving: 3MW

energy saving: 24GWh/a

cost saving: 350.000€/a

Energy Efficiency in IPPC Installations G. Bachmann 13

- The Environmental Managers -

Conclusion

Allplan carried out energy efficiency programs called : in

• Austria • Hungary• Netherlands • Czech Republic• Germany • Finland• Switzerland • Romania• Slovenia • …....• ….and find savings each time

Energy Efficiency in IPPC Installations G. Bachmann 14

- The Environmental Managers -

Energy Efficiency in IPPC Installations G. Bachmann 15

- The Environmental Managers -

Dr. Gerald BachmannALLPLAN GmbH

Schwindgasse 10, A-1040 WienTel: 01/ 505 37 07/ 43Fax: 01/ 505 37 07/ 27

gerald.bachmann@allplan.athttp://www.allplan.at

Thanks for your attention