The OP16 CHP Applications: Direct Drying and Heating

MSc. Stella Spazzoli

Application Engineer, OPRA Turbines
Presentation contents
Direct drying and heating applications: overview

Ceramic tiles factory

Gypsum board factory

Tissue mill

Chipboard factory

Bricks factory

Feasibility study and reference

Introduction: OPRA Turbines
 OPRA was established in the Netherlands in 1991

 OPRA provides on-site gas turbine driven energy solutions in the 1.5 – 10.0 MW power range
using the OP16 series of gas turbines

 OPRA is an internationally expanding, high growth company with unique, proprietary technology

 The OP16 combines robustness, simplicity and performance

 OPRA has market success for oil & gas and industrial and commercial CHP applications

 More than 130 OP16 gas turbines are sold worldwide

 The OP16 has accumulated more than 2 million operating hours

 OPRA is ISO 9001, DNV, API and GOST certified

 Power Output 1,876 kW
Introduction: OPRA Turbines Electrical Efficiency
Exhaust Flow
25.1%
8.9 kg/s
Exhaust Gas Temp. 573ºC
42,500 hours AND
Time Between Overhaul
3000 starts

Dual-fuel & low emissions

combustors (4)
Reduction
gear
High-efficiency (90%)
radial turbine

Bearings in
cold part
of engine

6.7:1 ratio
compressor
Packaged solution with a small footprint

 Small footprint Air filtration and

ventilation
 20 ft size container
Control panels
 20 ton

 Simple installation OP16 core engine

 Modular construction

 Ease of maintenance Fuel system

Generator
Introduction: Combustion Technology
OP16-3A OP16-3B OP16-3C

 Conventional  Dry low emission  Advanced diffusion

diffusion type combustor type combustor
combustor
 Gaseous fuels  Gaseous and fuels
 Gaseous and between 30-51 MJ/kg between 5-25 MJ/kg
liquid fuels between
20-70 MJ/kg  Diesel as back-up  High calorific fuel as
fuel back-up
 Dual fuel
operation
Low-calorific combustor

Conventional combustor
Presentation contents
Direct drying and heating applications: overview

Ceramic tiles factory

Gypsum board factory

Tissue mill

Chipboard factory

Bricks factory

Feasibility study and reference

Direct drying and heating
Scope Equipment Industry
Regulate water - Rotary dryer - Mined raw materials (gypsum, ceramic, cement,
content in the feed - Impact dryer etc..)
- Drum dryer
Complete drying of - Spray dryer - Stone, clay, glass, cement, kaolin, ceramics, etc..
slurry - Thin film dryer - Emulsion PVC and polymers
- Drum dryer - Milky and dairy products
- Dry soaps, detergents, dyes and pigments Fig. 1: Spray dryer
Pre-heat or dry - Furnaces - Metal fabrications
- Tunnel kilns - Coke processes
- Calciners - Glass and mineral industry
Release chemically - Rotary kilns - Bricks and ceramics with long residence time
bound components - Calciners - Gypsum, plasters, cement, limestone production
- Brick ovens - Pulp and paper and beet sugar industry
- Tunnel kilns
Remove water used - Conveyor and - Starch, stalk, husk, fruit peel
or created during tray dryer - Textile industry
process - Convection - Tissue paper
Fig. 2: Tunnel dryer
dryer - Fiber processing, pharmaceutical, polymer rubber
manufacturing
Presentation contents
Direct drying and heating applications: overview

Ceramic tiles factory

Gypsum board factory

Tissue mill

Chipboard factory

Bricks factory

Feasibility study and reference

Ceramic products: Introduction

Raw material Spray drying Forming Drying Glazing Firing

processing (Atomization) • Dry pressing • T=150–250ºC • Smooth and • T=1100–
• Weighing • T=400–600ºC • Extrusion • Continuous shiny surface 1300ºC
• Grinding • 5-7% Water tunnels • Optional • Kiln
• Mixing with • 2-3% water • Strengthen the
water tile
Ceramic tiles: Energy Distribution
 Energy accounts up to 30% of production costs
 Heat to power ratio suited for for gas turbine Energy consumption

 Ceramic tiles factory size: 3 million m2/year

Spray
Electricity
Drying
19%
25%

Utilities Energy level Energy Level

Inlet Outlet
Hot Air Spray Dryer 400 - 620 ºC 95 - 100 ºC Drying and
Firing
Hot Air Dryer 190 – 265 ºC 95 - 100 ºC 56%
Hot Air Kilns 1100 – 1300 ºC 100 - 150 ºC
Heat to Power Ratio=4:1
 Cogeneration layout: OP16 + Spray Dryer Legend
GT Exhaust
Air Intake Water/Steam
 Intake Air Flow Rate: 24,275 Nm3/h Burner Electricity
 Pressure: 1.01 bar(a) Combustion air
 Temperature: 15ᵒC Fuel System
Fuel
 Relative Humidity 60%  Fuel: Natural Gas
 LHV: 46MJ/kg (951 BTU/SCF)
 Pressure: minimum 12 bar(a) (175PSI)
 Temperature: max. 300ᵒC (572F)
 Flow rate: 710 Nm3/h (28.5 MMBTU/h)
Slurry
Ambient air Fuel
Air out

GT Exhaust
Flow Rate: 8.9 kg/s
Exhaust Temp.: 570ᵒC

Power Output
 Power Output: 1,860 kWe Powder
 Electrical Efficiency: 25.1%
Presentation contents
Direct drying and heating applications: overview

Ceramic tiles factory

Gypsum board factory

Tissue mill

Chipboard factory

Bricks factory

Feasibility study and reference

Gypsum board: Manufacturing Process
• Raw gypsum grinded
Crusher

• Gypsum is de-hydrated with hot air

Calcine • Stucco
system

• Stucco mixed with water and

Holding additives
tank

Forming • Slurry spread on gypsum paper

station

• Gypsum boards of desired size

Cutting

• Boards are dried in continuous

Dryer tunnels

Reference: ©2010 Georgia-Pacific Gypsum LLC. The Georgia-Pacific logo is owned by or licensed to Georgia-Pacific Gypsum LLC.
Gypsum board: Energy Distribution
 Energy accounts for 18% of manufacturing costs of gypsum
board
 Heat to Power ratio favorable for gas turbine
 Gypsum board factory size: 30 million m2/year

Utilities Energy level

Calcination system 500ºC - 850ºC [932°F - 1562°F]
(depending on calcine system design)
Board Drying 200ºC - 350ºC [392°F - 662°F]

Heat to Power Ratio=3.0:1

Heating is the kWh of fuel input

OP16 integration in gypsum board factory Legend
GT Exhaust
Water/Steam
Air Intake Electricity
 Intake Air Flow Rate: 24,275 Nm3/h Combustion air
 Pressure: 1.01 bar(a) Fuel
 Temperature: 15ᵒC
 Relative Humidity 60%

Fuel System Power Output

 Fuel: Natural Gas  Power Output: 1,860 kWe
 LHV: 46MJ/kg (951 BTU/SCF)  Electrical Efficiency: 25.1%
 Pressure: minimum 12 bar(a) (175PSI)
 Temperature: max. 300ᵒC (572F)
 Flow rate: 710 Nm3/h (28.5 MMBTU/h)
GT Exhaust
Flow Rate: 8.9 kg/s
Exhaust Temp.: 570ᵒC

Ambient air
Supplementary
firing Fuel
Post firing

Calciner Drier
High Temperature Low Temperature
Low mass flow rate High mass flow rate
Presentation contents
Direct drying and heating applications: overview

Ceramic tiles factory

Gypsum board factory

Tissue mill

Chipboard factory

Bricks factory

Feasibility study and reference

Tissue Paper: Manufacturing Process

Raw material Forming and Yankee Hood Calender Section Packaging and
processing pressing section Drier • Paper compressed Converting
• Tree fibers • Pulp spread on a • Tissue dried • Uniform thickness • Jumbo roll
• Mixing with water “wire” • Steam in the • Jumbo rolls in reel processed for end-
• Pulper • Water drained Yankee user
• De-watering press • Hot air in the hood
Tissue Paper: Energy Distribution
 Energy accounts for 12% of production costs
 Heat to Power ratio favorable for gas turbine
 Tissue mill size: 20,000 ton/y

Utilities Energy level

Hot Air 500 – 600ºC [932 -1112°F]
(depending on the paper quality)
Steam Low pressure saturated steam at 8 bar [116 psi] &
175ºC [347°F] Heat to Power Ratio=3.5:1
 Legend
Reference case – Tissue Mill in Italy Ambient air
GT Exhaust
Water/Steam
Fuel System Electricity
 Fuel: Natural Gas
Combustion air
 LHV: 46MJ/kg (951 BTU/SCF)
 Pressure: minimum 12 bar(a) (175PSI) LiBr Chiller GT Fuel
 Temperature: max. 300ᵒC (572F) Combustion air
 Flow rate: 710 Nm3/h (28.5 MMBTU/h)
T = 10 C
To stack
Power Output
 Power Output: 1,860 kWe
 Electrical Efficiency: 25.1% Mixer
Plenum Parallel firing To stack
GT Exhaust boiler
Flow Rate: 8.9 kg/s
Exhaust Temp.: 570ᵒC

Steam to
Payback time < 2 years Yankee
30% energy savings T = 400C
Presentation contents
Direct drying and heating applications: overview

Ceramic tiles factory

Gypsum board factory

Tissue mill

Chipboard factory

Bricks factory

Feasibility study and reference

Particleboard: Manufacturing Process
• Logs sawn into shorter lengths
Logs
cutting
• Bark removed

• Logs cut into flakes

Flaking • Flakes stored

• Water removed in dryer at low

Drying temperature

• Flakes mixed with resin

Forming • Flakes shaped into matts

Hot • Matts pressed with hot presses

pressing

• Surface smoothened and trimmed

Trimming • Chipboard packaged and shipped

References: Life Cycle Inventory of Medium Density Fiberboard: Beatriz Rivela, M Teresa Moreira and Gumersindo Feijoo
Particleboard: Energy Distribution
 Energy accounts up to 26% of Production Costs

 Heat to Power ratio favorable for gas turbine

 Factory Size: 150,000 𝑚𝑚3 /year

Utilities Energy level

Presses Oil @ 300ºC and 52 bar [572ºF and 755 psi]
(ΔT=50ºC [90ºF] )
Direct Drying 300ºC - 500ºC [572 ºF - 932ºF]
(depending on dryer technology and product wetness)
Heat to Power Ratio=3.8:1

Heating is the kWh of fuel input

OP16 integration in particle board Legend
GT Exhaust
Thermal Oil
Electricity
Combustion air
Air Intake
Fuel
 Intake Air Flow Rate: 24,275 Nm3/h
 Pressure: 1.01 bar(a)
 Temperature: 15ᵒC
 Relative Humidity 60%

Power Output
 Power Output: 1,860 kWe
Fuel System
 Electrical Efficiency: 25.1%
 Fuel: Natural Gas
 LHV: 46MJ/kg (951 BTU/SCF)
 Pressure: minimum 12 bar(a) (175PSI)
 Temperature: max. 300ᵒC (572F)
GT Exhaust
 Flow rate: 710 Nm3/h (28.5 MMBTU/h) Flow Rate: 8.9 kg/s
Exhaust Temp.: 570ᵒC

Ambient air
Supplementary
firing Fuel
Post firing

Thermal oil Thermal oil

Particleboard T=250⁰C Heat T=300⁰C
Drier Exchanger
Presentation contents
Direct drying and heating applications: overview

Ceramic tiles factory

Gypsum board factory

Tissue mill

Chipboard factory

Bricks factory

Feasibility study and reference

Brick Production Process
• Raw clay grinded
Crusher
Crushed and Molded
ground
• Water is added to sand
Molding • The mixture is shaped in bricks shape

Clay mine Extraction

• The water is evaporated in the dryer
Dryer • Long residence time

• Bricks undergo high temperature in

Kiln the kiln

• Bricks are packaged and delivered to

Packaging end customer
Brick factory: Energy Distribution
Cogeneration
 Energy accounts up to 30% of production costs Electricity,
Heat for the 8%
 Heat to Power ratio favorable for gas turbine Dryer, 23%

 Brick Factory Size: 170,000 Tons/𝑦𝑦

Heat (Total),
69%

Utilities Energy Level Inlet Energy Level Outlet

Drying process 170 ºC 95 - 100 ºC
Kilns 520 ºC, 620 ºC, 910ºC 65 ºC Heat to Power ratio 8.1:1
OP16 Gas Turbine integration with the process

OP16 - Kiln Integration OP16 - Dryer Integration

Presentation contents
Direct drying and heating applications: overview

Ceramic tiles factory

Gypsum board factory

Tissue mill

Chipboard factory

Bricks factory

Feasibility study and reference

Ceramic tiles factory: Feasibility Study (European Market)

Ceramic factory Size 2.7 million 𝑚𝑚2 (annual

production 7680 h/y)

Base Case Electricity Demand 1,876 kWe

Heat demand (atomizer 8.9 kg/s @ 570ºC

only)
OP16 Exhaust Heat* 4,500 kWth

€ 0.77
Natural Gas Price 0.028 €/kWh

CHP Electricity Price 0.084 €/kWh

 High Operational Savings: 32%

(0.77 million Euros)
 Payback 2.3 years
€ 0.0 € 0.2 € 0.4 € 0.6 € 0.8 € 1.0 € 1.2 € 1.4 € 1.6 € 1.8 € 2.0 € 2.2 € 2.4 € 2.6
Millions €

Annual operating savings Annual operating expenses Annual fuel expenses Annual electricity expenses

* ISO Conditions
** All calculations for CHP are including investment, EPC and LTSA costs for OP16.
Case study 1: Starch manufacturing plant

Turbine type
• OP16 – 3B dry low
emissions
Fuel type
• Natural gas
Power Output
• 1.78 MWe @ 24.7%
electrical efficiency
Thermal Output
• 8.7 kg/s @ 576ºC for
direct drying
Emissions
• < 15 ppmv NOx
Crespel & Deiters - Germany • < 10 ppmv CO
Case Study 2: Gypsum Board Manufacturing Plant
 OP16 already implemented in a Gypsum board factory in the Netherlands
→ Manufacturer of high-quality gypsum board
→ Annual production capacity: 28 million m2/year Gypsum board

 OP16 used in cogeneration mode

→ OP16 operating 24/7 island mode
→ Delivering complete power demand
 Exhaust split between calciners and board dryers: 5.8 MWth heat
→ Supplementary firing for high temperature calciners
→ High flow rate & low temperature drying for board dryers
Case Study 3: Particleboard manufacturing plant

Turbine type
• OP16 – 3A
Fuel type
• Natural gas
Power Output
• Up to 2MWe (site
conditions below 0ºC)
Thermal Output
• 9.3 kg/s @ 572ºC for:
• 2500 kW for heat up
thermal oil
• 2000 kW for dry
wooden flakes in 4
AS Repo Vabrikud - Estonia dryers
Conclusions and recommendations
 Direct drying used in several industrial processes:

 Wide variety of drying equipment (Temperature, residence time, mass flow..)

 OP16 optimal solution for dryers with operation temperature between 500 – 600⁰C
 OP16 heat can be directly used in furnaces or kilns but requires expensive modifications
 Low temperature applications possible by blending with fresh air

 Highly efficient generation of power and heat at the plant location

 Hot and clean OP16 exhaust can be used for direct drying of paper and starch products

 Low investment costs

 No additional equipment
 Modifications of existing burner
OPRA: Unique points
 High heat to power ratio (~3:1): OP16 generates 1,876 kWe with 5,300 kWth
100%
 Direct drying with hot and clean exhaust Fuel

 Possible to control exhaust temperature by duct firing

 Fuel flexibility

 High combined efficiency(~90%)

 Continuous and reliable power and heat with low emissions

 Low maintenance and operational costs 25% 3%

Electrical Losses 71%
 Compact and Modular: Easy integration into exisiting process energy High grade
thermal energy
Thank You