webinar - wind powered industrial process : seawater desalination

Dipl.-Ing. Joachim Käufler,SYNLIFT Systems GmbH, Berlin

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Wind Powered Industrial Processes

applications for

electrothermal processes andseawater desalination

Webinar, Leonardo ENERGY September 27, 2011


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Content

Company presentation

Wind powered Industrial Processes (WIP) – Basics

Application for electro thermal processing

Application for seawater desalination


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SYNLIFT Systems: Who We Are

project developer for turnkey wind power plants - worldwide

full range of services -from early stage investigation to final operation management

design and launch of innovative wind power applications -e.g. wind powered seawater desalination

consulting services for other wind power applications -e.g. wind powered electrothermal processing

© SYNLIFT Systems GmbH

®


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Renewable Energy Integration

The measures can be classified as follows :

Generation transition to more flexible power generation capacities;

Storage development of energy storage technologies at utility and consumer level;

Distribution new and reinforced connections between control zones;new and reinforced transmission lines;offshore grid installation;energy exchange between control zones and subgrids;

Consumption demand side management and load management;


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Load Management

For load balancing by load management two complementary approachesexist:

Interregional approach:

suitable trading and pricing or business models necessary; complex system with many power market players involved (loose connections); flexible, strong (and therefore costly) transmission system essential; smart grid philosophy;

Local approach:

complementary optimised generation/consumer entities coupled within local sub-grids on different levels;

major energy amount transferred between generation/consumer entities directly; minor energy amount exchanged temporarily with the next grid level upwards in both

directions; typical sub-grid applications are:

a) large scale power plants to supply large-scale consumer directly (e.g. commercial or industrial Combined Heat and Power plant);

b) PV-generators for private or communal self-consumption (micro- or mini-grids).


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Local Approach

energy costs =

power generation+ grid use+ fees & taxes

energy costs =

power generation+ grid use(+ fees & taxes)

Potential for local value creation with low and longterm stable costs...e.g. for energy intensive industrial processes...

grid

subgrid

conventional power ~~


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Energy Intensive Industrial Processes

Type 1 Type 2

Energy Consumption / unit produced (EC): low high

Total amount of units produced / period (TA): high low

Type 1: membrane processes - e.g. seawater desalination (RO) EC = 3,5 - 5,5 kWh / t TA = 500 - 300.000 t / d energy share of product costs: 30 - 60%

Type 2: electrothermal processes - e.g. aluminium melting EC = 410 - 690 kWh / tTA = 1 - 100 t / d energy share of product costs: 5 - 20% [0]

Processes with a high level of energy demand and/or energy share of product

costs ideal to be developed as… Wind Powered Industrial Process (WIP)…


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Power Generation Costs in EURcent/kWh

Price Increasein % p.a.

Volatility

Fossil fueled PG (> 5 MW) 3-10 3-5 medium to strong

Wind PG (> 1 MW) 3-10 < 1 low

PV PG (10 … > 1,000 kW) 12-32 < 1 low

Solar thermal PG (> 50 MW) 19-24 < 1 low

Economic prognosis for a power plant installed in 2010 (Fraunhofer ISE partly)

Wind power at many (coastal) sites is competitive with large-scale fossil fueled power generation ... already today … tendency increasing.

Wind power is mainly independent of price trends and volatility.

WIP Basics (I): Why Wind Power?


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The optimal system layout is mainly affected by the level of tariffs:

grid tarifflow: conventional processmedium: wind powered process – without LMhigh: wind powered process– with LM

feed in tarifflow: process with wind power supply

medium: wind powered processhigh: wind project with coupled process

WIP Basics (II): Relevance of tariffs


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Process with wind power(feed-in tariff level: low)

Wind Powered Process(feed-in tariff level: medium)

Wind Power with process(feed-in tariff level: high)

WIP Basics (III): Wind Power Capacity

1

2

surplus energy – windprocess energy – windprocess energy - grid

1 2 3

power

time

3power

time

power

time


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WIP Basics (IV): Wind Penetration

wind energy used directly for the process Wind Penetration (WP) = _________________________________

overall energy demand of the process

Most influential WP parameters are:

Wind power capacity (related to process capacity);

Storage capacity (on energy and/or product side);

Process load management and/or capacity;


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Process with wind power(feed-in tariff level: low)

Wind Powered Process(feed-in tariff level: medium)

Wind Power with process(feed-in tariff level: high)

WIP Basics (V): Wind Power Capacity

1

2

surplus energy – windprocess energy – windprocess energy - grid

1 2 3

power

time

3power

time

power

time


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WIP Basics (VI): Storage Capacity & Technology

Option 1: energy storage (nominal process capacity)

battery

Option 2.1: product storage (additional process capacity)

tank

Project integrated storage facilities increase the wind energy share directly used for the process (wind penetration) and decrease the energy exchange with the main grid respectively.

3 options of large-scale/multi-hour storage integration:

tank

Option 2.2: product storage (flexible process capacity)


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WIP Basics (VII): Process Load Management


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Wind powered electrothermal process (I)


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Wind powered electrothermal process (II)

Principle of load management in casting house industry

Type A: Variable melting & heat holding- buffering on energy side –

+ no new media & technology+ casting process unmodified+ known procedure (peak loads)- heat holding/storage ability vs.

temperature / insulating

Type B: Variable melting & casting- buffering on product side -

+ no new media & technology- casting process variable!

Prior solution: Type A


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Principles of Desalination

Vapour

Distillation Membrane Process

Cooling

HeatSeawater Condensate Seawater Permeate

Membrane


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Desalination Technologies

Seawater Desalination Processes

Phase-changeThermal Processes

Single-phaseMembrane Processes

Multistage Flash Evaporation (MSF)

Multi Effect Distillation(MED)

Vapor Compression (VC)Mechanical (MVC) &

Thermal (TVC)

Reverse Osmosis(RO)


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Thermal vs. Membrane Process

Thermal Process (MSF) Membrane Process (RO)

Energy Consumptionapprox. 13 kWhel/m³(70 kWhth + 3 to 4 kWhel)

3.5 – 5.5 kWhel/m³

Recovery 10% to 20% (brine recycling) 30 - 50 %

Investment [$/(m³/day)] 1,000 - 1,500700 - 1,500 (10 % thereof for membranes)

Chemicals [$/m³] approx. 0.03 to 0.05approx. 0.06 to 0.1(downwards, UF pretreatment)

Membrane Replacement n.a.every 5 years (2% of investment / year)

Brine, Quantity Distillate x 4 to 9 Permeate X 1 to 4

Brine, Quality Chemicals, Heat Chemicals

O & M Scaling disposalWashing of Filters (fortnightly)and Membranes (bimonthly)

Robustness HighLess High, Fouling Sensitivity,Feed water Monitoring !!!

Improvement Potential Low Medium


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Economics of Desalination

Constraints: Plant Capacity 30,000 m³/dayInterest Rate 7% Project Life 20 years Price Electricity 0.065 US$/kWh

MSF(therm.)

MED(therm.)

VC(therm.)

RO(membr.)

Specific Investment Cost [$/m³/day]

1,200 – 1,500 900 – 1,000 950 – 1,000 700 - 900

Total Cost Product [$/m³] 1.10 – 1.25 0.75 – 0.85 0.87 – 0.95 0.68 – 0.82

Source: Seawater and Brackish Water Desalination in the Middle East, North Africa and Central Asia, World Bank 2004


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Installed Desalination Technologies

1) Fig.: Source: 2004 IDA Worldwide Desalting Plants Inventory Report No 18; published by Wangnick Consulting

36,5

47,2

16,3

MSF RO MED, VC and Others

Distribution of installed plant capacity according to desalination process


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RO (I): Main Components

. High-pressure pump

Feed flow

Reverse osmosis membrane module

Permeate flow

Retentate flow

Energy recovery device

q Flow

p Pressure

F Feed

P Permeate

R Retentate

0 Ambient


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Preconditions for variable / wind powered operation

• broad load range to avoid excessive modularity and frequent activation/deactivation

sequences;

• low and uniform energy consumption per unit of product within the total load range;

• high process dynamic to adjust the process to the fluctuating wind power quickly;

Challenges

• common operation is uninterrupted at nominal capacity with constant parameters;

• no long-term experiences of membrane behaviour under strong variable operation;

Tests

• long-term tests with variable and constant operated membranes;

• real time computer simulations based on real wind speed series;

Results

• deterioration of the variable operated membrane could not be observed.

RO (II): Variable Operation


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SWRO-Membranes SW30-2540 at variable and constant feed pressure. Feed concentration of 36,4 g/l total salinity at 25°C.

RO (III): Variabel Operation (Tests)


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SYNWATER® The System (I)

SYNWATER® components: high process flexibility for low and strong wind periods;

SYNWATER® LM: load management system with:basic functionality: wind-dependent processing extended functionality: flexible tariff and demand scenarios for energy

and water considerable (smart grid)

SYNWATER® a modular system: wind turbine and plant capacities individually adaptable to project specifics;


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SYNWATER® The System (II)

1 Kernel modules (container option)2 UF membranes3 RO membranes4 Control room 5 Consumables, spare parts6 Media trench7 Feed water intake / beach well

Pre-processing facilities8 Potable water storage tanks/

Post-processing facilities9 Wind turbine10 Roof structure (textile option)

2

3

7

9

10

111

54

6

88

54

6

8


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desalination capacity of at least 500 m3 per day (no upper limit) grid-connected systems (on-grid) fully automated only commercially available standard components used

seawater desalination as WIP… what is meant:

seawater desalination as WIP … what is not meant:

small scale applications off-grid systems special solutions (e.g. mechanical coupling wind / RO)

Economic Aspects: Basic Assumptions (I)


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Economic Aspects: Basic Assumptions (II)

Project Wind Turbine (WT)

SWRO

project time [years]20

investment [€/kW inst. cap.] 1.250 - 1.450

investment [€/m3 daily cap.] 800 - 1.100

interest rate [%] 5 - 8

O&M cost [€/kWh]0,010 - 0,014

O&M cost [€/m³] 0,25 – 0,35

annuity factor [-] 0,0802 - 0,1019

feed-in tariff [€/kWh] 0,04 - 0,07

energy consumption [kWh/m³] 3,5 – 5,5

capacity factor [%]25 - 35

Considering the local wind conditions (capacity factor) and the energy consumption the WT capacity is designed to meet the annual energy demand of the plant (category: Wind Powered Process).

CDM effects are not considered.


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Economic Aspects: Fields of Application

Conventional desalination

Standard SYNWATER® capacities

Extended SYNWATER® capacities


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© SYNLIFT Systems GmbH

For SYNWATER® projects we are offering the following services...separately or as full-service package:

• Fact Finding Mission• Feasibility Study / Proposal• Investment Consulting / Financing• Technical Design• Turn-key Implementation• Operation & Maintenance• Training

Beside Delivery Transactions also BOT/BOO business models are negotiable.

profitable & sustainablealready today!

SYNWATER® Our Services


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Wind Powered Industrial Processes

profitable & sustainablealready today!

Thank you for your attention

www.synliftsystems.de

[email protected]