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Alfa Laval
10. Summary
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Agenda Savings opportunities:
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1. Heat Recovery Waste Energy savings
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1. Heat Recovery Waste Energy savings
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1. Heat Recovery Waste Energy savings
90
C
80 High-grade heat ~ 60-90C
Heating of buildings
70
60
30
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1. Heat Recovery Waste Energy savings
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3. In what industries can Utility Savings be found
Process Segments:
Metal/Mineral process
Inorganic chemical process
Pulp & Paper process
Refineries
Food and beverage
Industrial Manufacturing
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4. Within the Industries where are the
opportunities & applications?
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5. Within the Utilities where are the
opportunities and applications?
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7. Utility Equipment & Applications found in a plant!
Buying behavior Buying behavior
Cooling
Utilities Manager: Towers Process Engineers:
- Maintenance/shared service dept - Linked to core process
- Auxiliary equipment - Technical consultants
- Often outsourced to 3rd party - Process industry contractors
- Directly with Alfa Laval PTD
Alf
Filter
Fluid Cooling:
- H2O, Oil, Glycol
Chiller Steam
Generator
Process Water Cooling
- Interchanger Boiler
Heat recovery from return
Air Compressor
Hydraulic Power
Unit
Heat Recovery:
- Utility Space heating Uninterrupted
- Utility Tap water heating power supply unit
Alfa Laval www.alfalaval.com
8. Heat Recovery opportunities
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8. Heat Recovery Savings in Energy: kWh
Assumption:
Cost savings = Cost for energy kWh:
Double ie
192 if
12 months ?
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8. Heat Recovery Savings in Energy: kWh
Assumption:
Cost savings = Cost for energy kWh:
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Heat recovery if it can be utiliised
Eg: Domestic hot water pre heating or
space heating
Menu www.alfalaval.com
8. Heat Recovery opportunity
Cooling Tower (acting as heat source)
10 dC From mains
Before
Heat Recovery: 10 60 dC
After Heat recovery
10 dC From mains
Tap water,
Showers
20, 10 , 5 m3/h Heat 60 dC
cost
Kitchen etc
Boiler Tap water pre-heating
25 dC 35 dC
30 dC After HR: 30 60 dC
Waste
heat
40
20
10
m3/h
31-34 dC
X
35 dC 35 dC 37 dC
100 Oil cooling
m3/h
29 dC 29 dC 31 dC
GPHE design:
Delta T Hot side (CT side) 40 m3/h 35->25 GPHE design:
Delta T Cold side (HR side) 20 m3/h 30<-10 40 m3/h 35->23
20 m3/h 33<-10
Before HR: 10 60 dC
After HR: 30 60 dC ; 465- 116 kW recovered!
Additional savings:
- 10, 20 or 40 % relaxed load on Cooling Tower
- Less pump costs
- Less fouling & Maintenance
- Less water cost www.alfalaval.com
Example 1
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Example 1
Flow CT 30m3/hr 33 27
Flow Tap water ? Temp 10 31
Q=? M c dT= 30*6=180 kcal/hr divide by 0.86 = 209.3 kW
8hrs per day, 20 days per month, for 6 months
Saving for one year = 20.092 euro
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Example 1
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I will preheat for you water 10 m3/hr from 10 to 24
deg C.
This is saving for you in 1 yr.
This is 150 kW
This is 15,000 euro in one year
Based on 8 hr day, 20 day month 6 month per year
opetn.
multiplying by 96 (always remember 96)
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Example 2
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Example 2
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8. Heat Recovery opportunity Hot Oil:
Air Compressor Types 90 65 dC
Piston type w
Screw type w Radiator / Air cooling
Radiator/Air cooling
HOT OIL
HOT
Space / OIL
Tap water
heating
Space /
Heat recovery
Tap water
heating
HOT OIL
More info..
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8. Heat Recovery opportunity
Air Compressor Inside a Screw compressor
Water cooled
Air 6 bar: Air 6 bar: Air 6 bar : To Plant
-Humid -Humid -Atm temperature + 10 dC
-Oily -60-70 dC
-60-70 dC
Air Inlet:
1 bar AIR or
Humid
20-30 dC
Oil
65-90 dC
Heat recovery..
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8. Heat Recovery opportunity
Air Compressor
65 dC
60 dC 71 dC
5,4
m3/h Interchanger
Protects from
Dirt!
90 dC 40 dC
5,4 5,4
65 m3/h m3/h
dC 71 dC
60 dC 29 dC
Waste
Heat
To Before Heat recovery www.alfalaval.com
CT
8. Heat Recovery opportunity
Air Compressor Savings
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Heat 8 h / day 12
recovered 20 d / m months
6 months
Additional savings:
- Up to 100% relaxed load on Cooling Tower
- Less fouling & Maintenance
- Double annual savings on HR if used 12 months www.alfalaval.com
8. Heat Recovery opportunity
Steam generator Flash steam
10 dC
Steam
60 dC Waste !
From mains-
Flash Steam 1,2 bar
104, dC
104 dC
Steam Condensate
traps Tank
104 dC
Condensate water & steam133 dC
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8. Heat Recovery opportunity
Flash steam HR - Savings
Effect Effect Effect Cost Cost Hours Cost Days Cost Months Annual
Steam Heat used kW/h per per per per per per Saving
Flash Recovered 1 hour hour day Day Month Month Year
kW kW kW/h Euro Euro Euro Euro Euro
200 200 200 0,1 20 8 160 20 3 200 6 19 200
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8. Heat Recovery opportunity
Flash steam HR Correct HEX model
Evaporation www.alfalaval.com
8. Heat Recovery opportunity
Waste Water Textile Dye house
Wide gap
Plates:
Mechanical
filter
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http://www.ozenmensucat.com.tr/?sf=hksp&dl=en&st=smn
8. Heat Recovery opportunity
Waste Water Textile Dye house
Dye textile
Condensate
65 dC water 133 dC
Waste-Water
from dye textile 65 dC Flash
!! Steam
Steam Waste !
trap
Separator
65 dC Condensate
Waste Heat !! Tank
104 dC
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8. Heat Recovery opportunity
Waste Water Textile Dye house
After Heat recovery
Steam 133 dC / 3 bar abs
Hot water to dye machine at 60 dC
Dye textile
65 dC Condensate
20 dC water 133 dC
Flash
Steam
Waste !
Steam
trap
65 dC
60 dC Separator
Condensate
20 dC Tank
104 dC
15 dC From mains
Before Heat recovery www.alfalaval.com
8. Heat Recovery opportunity
Waste Water Textile Dye house
GPHE design:
Delta T Hot side (CT side) 40 m3/h 65->20
Delta T Cold side (HR side) 40 m3/h 60<-15
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Textile Waste Water Heat Cost Cost Investment Annual Monthly Months
40 m3 65--> 20 Recovered GPHE Piping Total cost Savings Savings Pay back
kW/h Euro Euro Euro Euro Euro period
2093 2,093 50,000 40,000 90,000 401,860 33,488 3
Based on
12 months
8 hrs per day
operation
Additional savings:
Annual savings based on dye machinery utilisation capacity,
faster filling with ready made hot water:
> 1,000,000 per year
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8. Heat Recovery opportunity
Waste Water Textile Dye house
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Other savings opportunities
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9. Maintenance, Energy & Water Savings
+
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9. Water, Maintenance or Energy Savings
Interchanger HEX
Inter-
changer
35 dC X
37 dC 35 dC
Dirt Cooling tower dirt etc:
Fouling &
CaCO3/salt Maintenance Fouling = Less efficiency
Chlorides & more Maintenance
etc 29 dC X
31 dC 29 dC
Higher Cost:
-High Maintenance
-Maintenance
-Factory downtime
-Pumping
-Less Heat transfer
-Downtime
Efficiency!!
-Energy kW
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9. Water, Maintenance or Energy Savings
Interchanger Protects from Fouling
37 dC
35 dC X
35 dC
No fouling
No maintenance!!!
Less pumping costs !!
High heat transfer efficiency
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9. Water, Maintenance or Energy Savings
Interchanger CaCO3 Calcium carbonate (Salt)
35 dC
37 dC
35 dC X
35 dC
Chlorides
With an Alfa Laval Interchanger:
-Protect plant loop from corrosion
Make up Water to compensate for
Evaporation -Safe to use carbon steel in plant loop
= Adds more Chlorides instead of stainless steel.
Slide 52 www.alfalaval.com
9. Water, Maintenance or Energy Savings
Interchanger Chlorides & corrosion
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9. Water, Maintenance or Energy Savings
Interchanger Chlorides & corrosion
37 dC
35 dC X
35 dC
37 dC
35 dC X
35 dC
Evaporating
Evaporating Water loop
Water loop
w chemicals
29 dC 29 dC
X
31 dC
Make up Water
Less Water
& Treatment chemicals Smaller
for full loop
partial 5 000 m3
loop Water
loop www.alfalaval.com
9. Water, Maintenance or Energy Savings
Interchanger HEX Savings
Savings:
1.Easier to clean fouling in a GPHE than in plant loop:
Less Maintenance - Less factory downtime
2. Less pumping costs
3. Carbon steel in plant loop - cheaper than stainless steel
4. Less chemicals or H20 treatment consumption for CT
5. Less water consumption www.alfalaval.com
9. Water, Maintenance or Energy Savings
Shell & Tube replacement
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9. Water, Maintenance or Energy Savings
Shell & Tube replacement
60-59 dC 1 hr
Shell & Effect Cost Cost Hours Cost Days Cost Months Heat
Tube used kW/h per per per per per per Loss
Heat loss 1 hour hour day Day Month Month Year 6 Months
kW kW/h Euro Euro Euro Euro Euro
11,6 11,6 0,1 1,16 8 9,28 20 186 6 1 114
11,6 11,6 0,1 1,16 8 9,28 20 186 12 2 227
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9. Water, Maintenance or Energy Savings
Shell & Tube replacement
Advantage vs
Have lower maintenance and operating costs, ensuring better long-term economy.
No heat losses
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9. Water, Maintenance or Energy Savings
Shell & Tube replacement
SAVINGS:
Less water consumption
Less energy consumption.
Less hold up volume fast response time
Less maintenance costs.
Less downtime
No heat losses
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9. Water, Maintenance or Energy Savings
Chiller by pass - 2 types of chillers
Evaporator
Condenser
35 dC 29 dC
Evaporator
Condenser
35 dC 29 dC
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9. Water, Maintenance or Energy Savings
Chiller by pass - Before by pass
Water cooled Condenser:
35 dC
7 dC 12 dC
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9. Water, Maintenance or Energy Savings
Chiller by pass - After by pass
Summer: Winter:
35 dC 11 dC
12 dC
38 dC
Condenser
29 dC 32 dC 6 dC
7 dC
Interchanger: Interchanger:
Only protects Protects
Evaporator
process from Dirt &
from Dirt & By pass
Corrosion etc! 7 dC Chiller & 7 dC 12 dC
12 dC
reduce
running cost !!
(bigger HEX)
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9. Water, Maintenance or Energy Savings
Chiller by pass - Savings
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9. Water, Maintenance or Energy Savings
Chiller by pass - Savings
Assumption:
Cost savings = Cost for energy kWh:
Effect Cost Cost Hours Cost Days Cost Months Annual
Effect used kW/h per per per per per per Saving
1 hour hour day Day Month Month Year
kW kW/h Euro Euro Euro Euro Euro
1 1 0,1 0,1 8 0,8 20 16 6 96
Chiller Energy Effect Cost Cost Hours Cost Days Cost Months Annual
Heat consumption used kW/h per per per per per per Saving
transfer Effect 1 hour hour day Day Month Month Year 6 Months
kW kW kW/h Euro Euro Euro Euro Euro
1 000 * 200 200 0,1 20 8 160 20 3 200 6 19 200
2 000 400 400 0,1 40 8 320 20 6 400 6 38 400
The by pass
Saves energy by reducing the
running hours of your chillers.
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9. Water, Maintenance or Energy Savings
Chiller by pass Before By pass
35 dC
29 dC
Condenser
With By pass
50 dC
Refrigeration
Compressor:
Heats up Freon
kW/?
or NH3
2 dC
Evaporator
12 dC
7 dC
Reduces kW
Reduce cost! www.alfalaval.com
9. Water, Maintenance or Energy Savings
Chiller by pass Dry cooler
No by pass
30 dC
Partial by pass
Complete by pass
5-10 dC 0 dC
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9. Water, Maintenance or Energy Savings
Chiller by pass Dry cooler Savings
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9. Water, Maintenance or Energy Savings
Chiller by pass Dry cooler Savings
Chiller Energy Effect Cost Cost Hours Cost Days Cost Months Annual
Heat consumption used kW/h per per per per per per Saving
transfer Effect 1 hour hour day Day Month Month Year 6 Months
kW kW kW/h Euro Euro Euro Euro Euro
1 000 * 200 200 0,1 20 8 160 20 3 200 6 19 200
2 000 400 400 0,1 40 8 320 20 6 400 6 38 400
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Water savings?
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9. Water, Maintenance or Energy Savings
Cooling Tower replacement - Savings
Water savings?
Alf
Filter
Save energy:
Minimize pressure drop
on HEX and ALF
https://youtu.be/_MCv6qyBwoE
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9. Water, Maintenance & Energy Savings
Sea & River water free cooling
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10. Save cost with Alfa Laval
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10. Save cost with Alfa Laval
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10. Save cost with Alfa Laval
Thankyou !
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