By use of trigeneration system, which generates 1.4 MW electricity and 1,9 MW heat, 970kW cooling is obtained from waste heat. By heat recovery, which is generally ensured from the non-utilized oil cooling system, the outdoor swimming pool is heated to 24°C in winter.
The system, which was put into operation in 2001, ensures an average energy saving of € 400.000 in a year and contributes to the protection of the environment by enabling CO2 reduction of 4.780 tons with a natural gas saving of 930.000 Nm3 by ensuring quality energy on constant basis.
Tata Steel performs the manufacturing of painted steel sheet in its factory, which is located in Adapazarý Hanlý OSB. The sheets, which are cleaned up in 7 pools by the help of cleaning process, are painted and the process is completed after drying the painted sheets in furnace at a temperature of 300°C.
The water is boiled in 7 pools by 7 boilers, each of which is 200 kW, and the waste heat of 20 percent of the exhaust gas is reduced from 220 °C down to 120 °C by the use of heat recovery system and then the pool water pre-heating is performed and the lacking temperature was ensured by the burning of the said 7 boilers.
% 100 temperature of the exhaust (47.000 m3/h) of the exhaust is reduced from 230°C down to 100°C by the use of the newly built 1 TEV®-KZ special exhaust exchanger of 300 m2 and the in-pool temperature of 225 tons/h water flow rate is ensured to be 60 - 70°C. While 300.000 kcal/h heat is recovered before the project by the use of TEV®-KZ application, in total some 2.212.000 kcal/h heat recovery is ensured.
As a result: Some heat recovery difference of 1.912.000 kcal/h is ensured. (1.912.000 / 9250/0,65 x 5 x 50 x 24= 1.908.025 Nm3/year) fuel saving and annually 820.450.-TL/year additional fuel cost is reduced.
At this point, still additional fuel saving will be achieved by ensuring the pre-heating of the fresh air input into the furnace with the waste heat released into the air by 100°C 16.000 m3/h exhaust.
At this point (47.000 x 1,2 x 0,35 x (100 - 35)) / 9250 / 0,65 x 5 x 50 x 24 = 1.280.000 Nm3/annual fuel saving will be ensured and 550.500.-TL/fuel cost will be reduced.
By an investment sum of only TL 400.000, TL 820.000, that is 1.900.000 Nm3 fuel saving was ensured and the investment made financed itself after only 6 months and started making profit.
In the painting and chemical finishing facility of Arý Tekstil, production is performed by a capacity of 20 tons/day. 7-8 bars of steam, which is needed by the process, is ensured by 1 coal fluid-bed steam boiler of 14 tons/day.
Burning/combustion parameters of the steam boiler does not operate on the basis of real measurement and as emission values cannot be controlled, there were some operational and environmental problems.
2 coal feed valves at values of 7,2 tons/h - 8,3 bars - 175,6 °C work at 25,9% feed load and coal feed were ensured at a capacity of 1,7 KG/VALVE CIRCLE – VALVE.
As a result: By 1.989 kg/h coal consumption, Q= 7200 x (852 – 102)= 5.400.000 kcal/h heat is produced by use of coal with thermal value of 3200 kcal/kg.
For controlling the burning, required parameters are obtained by burning efficiency control by mounting Oxygen and Carbon Monoxide sensors.
For the boost of burning efficiency and increase of thermal value, fuel saving was ensured by use of TEV-MAG thermo-magnetic fuel saving system.
1 coal feed valve at values of 7,2 tons/h – 8,3 bars - 180.6°C works at 25,9% feed load and coal feed were ensured at a capacity of 1.7 kg/ 1 valve circle.
As a result: 5.605.920 kcal/h heat is generated by some coal consumption of 7,7x45x0,25x60 = 1.101 kg/h.
B = 5.605.920/1.101 B = 5.091,6 kcal/kg
Fuel saving ratio = 1 - (1/(5.091,6 / 2.717)) = 46,6 %
Also, electricity consumption was reduced by 50%.
Some investment of TL 500.000 was made for achieving 46% coal saving, some annual saving of TL 800.000/year was ensured and the investment was able to finance itself after a period of 6 months and started making profit.
Some fuel saving of 25% was achieved by use of TEV-MAG Thermo-Magnetic fuel saving in the 2.6 MW natural gas-operated steam boiler. After putting the system into operation one 0,7 MW natural gas-operated Hot Oil Boiler was deactivated and therefore, additional fuel saving and electricity saving was ensured. After the project, some annual natural gas saving of 300.000 Nm3 and 540 tons of CO2 decrease was ensured along with environmental contribution.
Some fuel saving of 35% was achieved in the 2.6 MW natural gas-operated steam boiler thanks to TEV-KZ, and in the 2.1 MW hot oil boiler by use of TEV-MAG, TEV-KZ fuel saving systems. Exhaust temperatures of steam boilers and hot oil boilers were decreased from 240°C down to 45-50°C, and the recycled exhaust temperature was used during hot water production of 60°C and decreased the need for hot oil temperature and allowed the closure of one 1.15 MW hot oil boiler. As a result, additional fuel and electricity saving was achieved. After the project, some annual natural gas saving of 400,000 Nm3 and 720 tons of CO2 decrease was ensured along with environmental contribution.
Some fuel saving of 20% was achieved by use of exhaust temperature recycling system and 150 tons (24-60 °C) hot water saving was achieved in the 4.5 MW natural gas-operated steam boiler by use of the TEV-KZ Thermo-condenser fuel saving system. After the project, some annual natural gas saving of 300.000 Nm3 and 540 tons of CO2 decrease was ensured along with environmental contribution.