EnerDry ApS
Arne Sloth Jensen
Tørring af roepulp og andre produkter I overhedet damp.
TEKNOLOGIST INSTITUT Århus
Oktober 2008
EnerDry ApS
1. Udvikling af damptørringsteknikken.
2. Hvordan virker tørreren.
3. Kapaciteter
3. Næsten 100% energibesparelse 4. Pulp som brændstof
5. Miljø
6. Forøget produktion 7. Udviklingen i USA.
8. Damptørring i Europa.
9. Økonomi
10. Tørring af andre produkter.
11. Energibesparelse og reduktion af CO2 emission.
12. Konklusion.
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3,5 bar Steam
Heat
Wet pulp
Dry pulp
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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.
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EnerDry ApSBox 6'' x 6'' for up to 5 bar Window
Cell for
drying small samples
in steam. Superheated
steam
Steam from top also possible.
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EnerDry ApSPressure control
Product out Product in
Flow control
Boiler 5 bar
Electric super-
heater
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Installation pilot en construction 1983
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l’Installation pilot 1983
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L’Installation pilot de debut.
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L’Installation pilot modifiée
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Prototype 1985
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Prototype
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Le sécheur. Sucrerie de Nangis
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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
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Energy supplied
Supplied 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
. evap lb
1076 Btu lb =
110229 kWh 34722
= 2501 kJ/(kg evap)
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Energy consumption
0 200 400 600 800 1000 1200 1400 1600
Btu/lb evap.
Drum Dryer Steam Dryer
Returned energy
Used energy 19 Btu/lb evap Supplied energy 1076 Btu/lb evap Supplied and
used energy
1400 Btu/lb evap
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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
Loss 20.4
167.6
Drum Dryer Boiler
28 barg 300ºC
Turbine
Evaporators
18.5 31.3
18.5 1 9 8
80.8
31.8 80.8 89.8
21 t/h
Total93.6
Energy flow in a factory with drum drying of pulp.
10 000 ton beets / day MW energy flow
0.5
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Steam Dryer
115.3 115.1
19
52.6
Loss 0.1 Loss
19.2
59.9
2.6
53.9
2.6
48.3
11.2
7.8
2 6 8
53.9
48.3 Boiler
28 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
Total93.6
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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.
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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.
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Evironmental improvements.
Tørringen finder sted I et lukket system. Derfor er der ingen emmission til atmosfæren. .
* Intet Støv
* Ingen VOC (lugt)
* Ingen CO
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Intet støv til atmosfæren.
Men dampen fra tørreren har 2ppm små partikler, som ender som suspended stof i kondensatet.
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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.
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Vandfasen forøger BOD belastningen på sukkerfabrikken spildevand med
ca. 2%
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Tabt produktion fra forbrænding.
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Steam dried beet pulp vs. Drum dried beet pulp
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Loss of product by burning in drumdriers.
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Steamdryers in USA
50 t/h EnerDry 2007
Size H MN
American Crystal Sugar
East Grand Forks
38 t/h 50 t/h
EnerDry 2006 Size H
MI Michigan
Bay City
73 t/h 71 t/h
EnerDry 2006 Size J
ID Amalgamated
Nampa
40 t/h 50 t/h
EnerDry 2003 Size H
ND Minn-Dak
Farmers
2 x 40 t/h 2 x 40 t/h
Niro 1999.
Rebuildt by EnerDry 2004 2 x size 10
MN SMBCS
Used capacity Nominel
capacity Supplier
Dryer State
Compagny
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Piping around steam dryer Nampa
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Steamsystem at Nampa sugar factory
Steam System Nampa
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*Calculated based on operation data. Not tested due to steam system and lack of pulp
83 t/h 31 t/h
114 t/h 14/28 bar
Calculated max Capacity*
73 t/h 27 t/h
100 t/h 13,5/24,8
bar Avarage 24h
14 Febr.
2007
71 t/h 28/28 bar
Guarantee
67t/h 14/28 bar
Guarantee
Evap Pulp out
Pulp in Steam
supply
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• 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.
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Pulp Dryer Stacks Before Steam Drying Operation
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Pulp Dryer Stacks After Steam Dryer Operation
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Steamdryer at Bay City, Michigan
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The steamdryer at Minn-Dak Farmers, North Dakota
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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
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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 på
plads begynder investeringerne så småt igen.
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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).
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Economy
Minn-Dak Farmers.
Max 50 t/h evaporation 2003; 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.
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Economy
In 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 €
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Economy
Yearly profit from steamdrying.
Gain per year.
Saving on gas:
45000x3000/3600/1000=37,5 MW
37,5x29x24x100= 2,61 mill € No pulp burnt
1,5x100x24 180= 0,65 mill € Saving on labor and
Maintenance. 0,20 mill €
Total 3,46 mill €
Lost power production -0,25 mill € Net gain per 3,21 mill € 100 day campaign
The numbers are based 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.
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Why dry wet Solid Fuels?
• Burning wet fuel use primary energy to evaporate H
2O
• The water vapor takes up volume in boiler and the exhaust gas cleaning system, reducing the capacity.
• Wet fuel give more pollution
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Wood chips for district heating
With steam drying and power production
Power produced: 34,5 MWe District heat: 117,4 MW
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Steamdrying of other products.
2 steamdryers for wood chips and bark in
Sweden.
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Våde brændsler, som bør damptørres.
• Træflis
• Bark
• Bagasse
• Brunkul
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Tørret slam fra aerob
vandrensningsanlæg
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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 ethanol production. 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.
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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.
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67,5 t/h Boiler feed water 134°C
10540 kW
18399 kW
50,4 t/h, 3,0 bar, 145 °C, 2750 kJ/kg, 38500 kW
Boiler Gas fired 43 bar Max 90 t/h
AIR
Alfalfa 20%
DS 116 t/h
Predied Alfalfa 30,5 % DS, 76 t/h
Dryed Alfalfa 90 % DS 25,8 t/h
40 t/h evap.
50 t/h evap.
SizeJ
30°C 126 kJ/kg 1764 kW
44595 kW 1,11 MWh/ton evap.
959 kcal/kg evap.
Energy from boiler house.
43512 kW
0,48 MWh/ton evaporated 415 kcal/kg evaporated.
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71,1 t/h 54411 kW
Boilerhouse Gas fired 43 bar
AIR
Pulp 28%
DS 28 t/h
Dried pulp 8,7 t/h 90%DS Pulp feed
28% DS 102,6 t/h
19.3 t/h evap.
Size J
28950 kW 1,5 MWh/ton evap.
1290 kcal/kg evap.
70,7 t/h evap.
71 t/h
94208 kg/h 28 bar, 250°C 2865 kJ/kg 74974 kW
16972 kg/h 4625 kW 76836 kg/h
20938 kW 77236 kg/h 70349 kW
Dried pulp 31,9 t/h 90%DS
Heat from Vacuum pan vapour
Dried pulp 40,6 t/h 90%DS
Gas consumption in boiler house does not increase compared to 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 of this 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 the old installation.
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Boiler 1 Gas fired 43 bar Max 90 t/h
Boiler 2 Gas fired 43 bar Max 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
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2 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 to condens er
1 A+
B+
C
0
New 4000 m2
4 5 3
91 t/h Boiler feed water
50 bar, 208 °C Directly into boiler
9 t/h 100 t/h
3,7bar a
2
4,6 MW
19 bar a
2 size H
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6792 t CO2
reduction per year per invested mill € Investment:
10.6 mill €
No raw material used
72000 t CO2
reduction per year 200 ton coal per day not fired.
600 t/day CO2 emission avoided.
In 120 days per year
Nampa Steam dryer
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595 t CO2
reduction per year per invested mill € 6792 t CO2
reduction per year per invested mill €
Investment: 200 mill € Investment:
10.6 mill €
2200 ton/day wheat is used.
700 ton/day DDGS produced No raw material
used
119000 t CO2 reduction per year 72000 t CO2
reduction per year
Production 8000 hl/day.
Avoided CO2 emission 1200 t/day CO2 from cultivation: -250 t/day CO2 from boilers: -600 t/day Net CO2 reduction: 350 t/day In 340 days a year.
200 ton coal per day not fired.
600 t/day CO2 emission avoided.
In 120 days per year
An ethanol factory on wheat Nampa Steam
dryer
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1083 t CO2
reduction per year per invested mill €
595 t CO2
reduction per year per invested mill € 6792 t CO2
reduction per year per invested mill €
Investment: 12 mill € Investment: 200 mill €
Investment:
10.6 mill €
No raw material used 2200 ton/day wheat is used.
700 ton/day DDGS produced No raw material
used
13000 t CO2 reduction per 119000 t CO2 reduction per year year
72000 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/day CO2 from cultivation: -250 t/day CO2 from boilers: -600 t/day Net CO2 reduction: 350 t/day In 340 days a year.
200 ton coal per day not fired.
600 t/day CO2 emission avoided.
In 120 days per year
4 x 2 MW windmills An ethanol factory on wheat
Nampa Steam dryer
