Bronswerk was present on #ICCI2014 in Turkey last week. Energy efficiency is a big topic for the Turkish economy and society. This presentation is about improvement areas for energy efficiency. The 1st area is : Newbuilds : start at the design: reducing energy consumption of process equipment. The 2nd area is: Upgrading of Installation: High efficiency fans & pumps: increase plant capacity and efficiency. Interesting ROI case studies included. Enjoy reading and feel free to contact us!

1. ICCI 2014 FACS - 26/4/2014

2. Dynamic Heat Exchange Solutions
Air-cooled coolers & debottlenecking, reduction of plot
space, noise and energy consumption
Femke Schaëfer-Wering
Istanbul – April 26th , 2014
ICCI 2014 FACS - 26/4/2014

3. Topics:
• Short introduction to Bronswerk Heat Transfer®
• Improvement area’s for energy efficiency
• Case studies
ICCI 2014 FACS - 26/4/2014

4. Introduction
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5. ICCI 2014 FACS - 26/4/2014

6. Our markets:
Sustainability Service & Maintenance
Power
Oil
Gas
Chemical
Air Handling
Food Processing
ICCI 2014 FACS - 26/4/2014

7. ICCI 2014 FACS - 26/4/2014

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9. What we do:
• Thermal designs:
based on:
 Aspen/HTFS
 HTRI
 HEI
 Computational Fluid Dynamics
 Hysys
ICCI 2014 FACS - 26/4/2014

10. What we do:
• Mechanical designs:
 - ASME
 - EN13445
 - AD2000
 - RTOD
 - PD5500
 - CODAP
 - GOST
 FEM analysis
ICCI 2014 FACS - 26/4/2014

11. What we do :
• Process design:
Process optimization
ICCI 2014 FACS - 26/4/2014

12. What we do :
• Equipment:
 Heat exchangers
 Air cooled coolers
 And other process
equipment
ICCI 2014 FACS - 26/4/2014

13. What we do :
• Materials:
 Titanium
 (Super)Duplex
 Nickel-Alloy
 Inconel
 Other exotics
ICCI 2014 FACS - 26/4/2014

14. What we do :
• Systems:
 Incl. controls
ICCI 2014 FACS - 26/4/2014

15. What we do :
• Site work:
 Erection
 Assembly
 Start up
 Commissioning
 Service
ICCI 2014 FACS - 26/4/2014

16. What we do :
• Service & Maintenance:
 Upgrading
 Debottlenecking
 Inspection
 Specialist
maintenance for
machines operating
hazardous materials
ICCI 2014 FACS - 26/4/2014

17. Our focus on innovation:
• Product development
• System solutions
• New technology
 Whizz-Wheel® fans
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19. Area’s for improvement
ICCI 2014 FACS - 26/4/2014

20. One: Newbuilds
Start at the design: reducing energy consumption of process equipment
 Fans of the air cooled coolers,
condensers & combustion blowers
 Pumps/compressors
 Our high efficiency fans reduce
energy consumption by 50%
 Our high efficiency pumps/
compressors reduce energy
consumption by 20-40%
ICCI 2014 FACS - 26/4/2014

21. Two: Upgrading of Installation
High efficiency fans & pumps: increase plant capacity and efficiency
 Approx. 200 kW per condenser
 Approx. 600 kW combustion
blowers
 Approx. 1000 kW pumps
 Use these kW’s more efficiently
 Increasing output
ICCI 2014 FACS - 26/4/2014

22. Overall Plant Performance
Improve plant efficiency; increasing the overall efficiency by 6%
 The plant efficiency is approx. 30-40%
 2% is used for fans of the
condenser
 6% is used for the fans of the
combustion blowers
 Saving 50% on fan power
 10% is used for pumps
 Saving 20% on pumping power
 Increase overall efficiency by 6%
ICCI 2014 FACS - 26/4/2014

23. Case studies
ICCI 2014 FACS - 26/4/2014

24. Current situation:
•Huge plot space requirement
•High power consumption for air coolers
•Big influence on CAPEX & OPEX
Case study 1 – High efficiency cooling
ICCI 2014 FACS - 26/4/2014

25. Case study 1 – High efficiency cooling
•New fan design based on
aerospace technology
•Intensified heat transfer
•Over 50% reduction in
power consumption
•OR
•Over 30% plot space
reduction
ICCI 2014 FACS - 26/4/2014

26. Original design based on standard air coolers;
• Absorbed electrical power: 1143 kW
• Plot space used: 4224 m²
• Noise power emission: 101 dB(A)
Case study 1 – High efficiency cooling
ICCI 2014 FACS - 26/4/2014

27. Improved design based on high efficiency air coolers (with Whizz-Wheel® fans);
Old New
• Absorbed electrical power: 1143 kW 528 kW
• Plot space used: 4224m² 2974 m²
• Noise power emission: 101 dB(A) 94 dB(A)
Case study 1 – High efficieny cooling
ICCI 2014 FACS - 26/4/2014

28. Benefits;
• Noise reduction: 7 dB(A)
• Size reduction: 1250 m² = 29%
• Power consump. red.: 615 kW = 53%
• Opex savings: € 492.000,- / yr
Figure 3: comparative
Figure 2: high efficiency designFigure 1: standard design
Case study 1 – High efficiency cooling
ICCI 2014 FACS - 26/4/2014

29. VS
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30. Debottlenecking / Increasing output
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31. Case study 2 – Debottlenecking/ Increasing output
• 35% more cooling air
• 10-15% more production
• € 700 million gas production
• € 70 million additional
• Debottlenecking investment: € 5,5 million
ICCI 2014 FACS - 26/4/2014

32. Case study 2 – Debottlenecking / Increasing output
Restrictions:
• Maximum noise level
• Production capacity
down to 60%
Results:
• Elimination of all
noise issues
• Production up to
100%
Bonus:
• 56% savings in
energy consumption
ICCI 2014 FACS - 26/4/2014

33. Case study 2 – Debottlenecking/ Increasing output
Restrictions:
• Lower noise level or
plant shut down!
Results:
• All 65 fans installed
• Elimination of all
noise issues
Bonus:
• 53% savings in
energy consumption
ICCI 2014 FACS - 26/4/2014

34. Sensitivity for wind velocity
ICCI 2014 FACS - 26/4/2014

35. Current situation:
Steam turbine condenser:
 Power consumption: 1200 kW
 Opex: € 768.000,- / yr
 Performance testing for air cooled
condensers based on official guidelines
 Average wind speed should remain
under 3 m/s
 Maximum Beaufort 2
 At higher wind speeds no performance
guarantees
 In most cases there’s more wind!
ICCI 2014 FACS - 26/4/2014
Case study 3 – Sensitivity for wind velocity

36. Two solutions:
 Larger cooler with low energy consumption fans
 Slight breeze
 Negative effect on operation of the fans
 Negative effect on condenser vacuum
 Generating less electricity to the power grid
 Same cooler with more air because of high efficient cooling
 Reduce effect of crosswinds
ICCI 2014 FACS - 26/4/2014
Case study 3 – Sensitivity for wind velocity

37. Case study 3 – Sensitivity for wind velocity

38. Benefits:
 Lower power consumption in majority of operating conditions and
seasons:
 Additional bonus: over 50% savings on energy consumption:
 € 384.000,- /yr
ICCI 2014 FACS - 26/4/2014
Case study 3 – Sensitivity for wind velocity
Wind effect on yield
Air quality (%) in: < 3 m/s 5 m/s 7 m/s
Beaufort < 2 3 < 4-5
Conventional design 100 77.5 49.2
High Efficiency 100 91.6 79.2

39. Future perspective for gas evaporation plants
ICCI 2014 FACS - 26/4/2014

40. Source: Siemens USA
FACS - 14/10/2013LNG Tech Global Summit 2013
Case study 4 - Regasification

41. Original design based on conventional fans
• Nr. of fans per vaporizer:` 4
• Diameter fan: ca. 1 m
• Design flow: 108 m3/s
• Design Δp: 150 Pa(nom.)
• Absorbed vaporizer power: 45 kW
FACS - 14/10/2013LNG Tech Global Summit 2013
Case study 4 - Regasification

42. Case study 4 - Regasification
Redesigning the air heated vaporizer with the Whizz-Wheel®
Improved design based on Whizz-Wheel® fans
Option 1: reduced energy consumption
• Nr. of fans per vaporizer: 1
• Diameter fan: 3 m
• Design flow: 108 m3/s
• Design Δp: Whizz-Wheel®
• Absorbed vaporizer power : ~10 kW
• Reduction in energy consumption: > 70%
FACS - 14/10/2013LNG Tech Global Summit 2013

43. Case study 4 - Regasification
Redesigning the air heated vaporizer with the Whizz-Wheel®
Improved design based on Whizz-Wheel® fans
Option 2: reduced plot space
• Nr. of fans per vaporizer: 1
• Diameter fan: 3 m
• Design flow: 216 m3/s
• Design Δp: Whizz-Wheel®
• Absorbed vaporizer power: ~ 45 kW
• Reduced plot space: 50%
FACS - 14/10/2013LNG Tech Global Summit 2013

44. Case study 4 - Regasification
Redesigning the air heated vaporizer with the Whizz-Wheel® fan
Benefits:
• More air flow: (2x)
OR
• Reduced power > 70%
OR
• Lower number of vaporizers: 50%
• Weight reduction (offshore): 50%
• Reduced plot space: 50%
• Cost saving on piping, cabling: 50%
FACS - 14/10/2013LNG Tech Global Summit 2013

45. Summary
Yes, Bronswerk Heat Transfer can help your power plant become
more sustainable and profitable at the same time:
ICCI 2014 FACS - 26/4/2014
Air Cooled Coolers & Efficiency
Reduction of energy consumption Power consumption reduction up
to 50%
Reduction of plot space Or up to 30% in plot space area
Debottlenecking Reduced effect of crosswinds and
higher yield
Reduction of noise Noise reduction 4-6 dB(A)

46. Thank you for your attention.
Questions please
ICCI 2014 FACS - 26/4/2014

47. How to contact us:
www.bronswerk.com
facebook.com/bronswerk
Linkedin.com/company/bronswerk-heat-transfer
twitter.com/bronswerk
And come visit our booth in the central hall
ICCI 2014 FACS - 26/4/2014