FEATURE BOILERS, PUMPS & VALVES
CAPITALISING ON BIOENERGY and waste heat in industry
Although the long-term trend for energy prices is still upward it will not necessarily impact upon factory gate prices for goods, according to Saxlund International’s MD Matt Drew
solutions, typically in the 2 to 5 MWe range, will increase in the UK helped by the fact that they are easier to fund and quicker to implement than much larger biomass power stations. Aside from fuel cost savings there are financial incentives including the Renewable Heat Incentive (RHI). Qualifying CHP schemes with appropriate CHP Quality Assurance programme (CHPQA) certification will be eligible to a range of benefits including Renewable Obligation Certificates, Carbon Price Floor (heat) relief, Climate Change Levy exemption (in respect of electricity directly supplied) and Enhanced Capital Allowances (ECA). It is relatively easy to convert existing
I
ndustrial process heat is vital to most manufacturing and industrial processes,
supplying the energy needed to produce basic materials and commodities from steel, cement and composites to pharmaceuticals, chemicals and food and drink. Whether it is in the form of process steam, a major energy source for chemical industrial processes, hot water and oil or the massive thermal energy used by the cement sector for the calcination of limestone, industry and manufacturing depend on process heat. However, producing steam is extremely energy intensive and the combustion of fossil fuels accounts for a significant proportion of it. Furthermore, the long- term trend for energy prices is still upward. Will this impact upon factory gate prices for goods? Not necessarily - biomass fired solutions can reduce fuel and energy costs, an area in which Saxlund has been involved for several years in the UK and Europe. Since 1988 the UK cement industry has cut carbon emissions by 40% and measures to reduce dependency on fossil fuels by supplementing these with waste derived alternatives plays a key part. Of the 11 cement plants in the UK for example, at least 10 operate some form of alternative fuel system to displace a proportion of the coal they would normally use to fire their kilns.
10 MAY 2015 | FACTORY EQUIPMENT This same technology is available on a
smaller scale for other industrial users with their own heat centres. Biomass combustion solutions provide good quality industrial heat with multiple heat consumers on the one combustion unit including low and high pressure steam, hot water boilers, thermal oil and flue gas dryers. Organic Rankine Cycle (ORC) systems can be used for electricity production from combustion processes by capturing the combustion energy using thermal oil in place of steam. One major benefit is that working pressures (typically 10 bar) are much lower than steam so operational costs and investment are reduced. Combined heat and power (CHP) or cogeneration is becoming an increasingly attractive option with the potential to reduce energy costs by 20% or more. Generating heat and power simultaneously is up to 80% more efficient and carbon emissions are reduced. Combine CHP with biomass fuels and the gains are doubly attractive. Woodchip biomass or pellets from sustainable sources or waste wood are significantly cheaper than fossil fuels and better for the environment with the potential to cut CO2 by as much as 90% compared to gas. While continental Europe is ahead of the game the number of small-scale biomass-fired CHP energy
Bioenergy and solutions delivering green heat and power from locally sourced fuel present an opportunity to reduce energy costs while improving environmental performance
industrial heat centres to biomass combustion. Process steam boilers and industrial engines can be optimised to produce electricity with instant benefits from new feed in tariffs. Powerbox solutions developed by Saxlund’s sister company Opcon Energy Systems enable the production of emission-free electricity from waste or surplus heat including saturated steam suited to process industries. In many instances the industry requires costly cooling solutions when waste heat could be generating electricity. Large diesel or biofuel generators can benefit by utilising low grade waste heat such as jacket cooling and combustion gas cooling. Power generation can be increased typically by 5-10% without the need for larger engines or more fuel; gas fired generators in food processing and refrigeration can benefit. For energy managers and large industrial users bioenergy and solutions delivering green heat and power from locally sourced fuel present an opportunity to reduce energy costs while improving environmental performance. Of course, fuel handling expertise for
biomass and an accurate assessment of a site’s heat and power demands is crucial. Sensible engineering practices and proven technology are needed to ensure biomass CHP plants meet expectations and deliver planned returns.
Saxlund T: 02380 636330
www.saxlund.co.uk
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