THERMAL SCIENCE

International Scientific Journal

Thermal Science - Online First

online first only

Steam system optimization of an industrial heat and power plant

ABSTRACT
Improvement of the energy conversion processes efficiency helps to achieve a more reliable energy supply, a cleaner environment, more competitive businesses, and higher living standard. Industry data indicate significant potential for improving the efficiency of steam systems and minimizing their operating costs by implementing various measures. The present work is a result of a systematic approach for energy performance analysis and identification of opportunities for optimizing the steam-condensate system of the combined heat and power plant ESM Energetika, Skopje, R. N. Macedonia. The boiler plants provide superheated steam used in a hot-water station for the district heating system, for electricity generation, and as process steam for industrial customers. As the main operating costs of the plant stem from the natural gas consumption, the implementation of a set of energy efficiency measures will lead to its reduction, accompanied by less environmental impact. As a result of the system analysis, a number of energy efficiency measures have been identified. For each measure, the impact on individual parts of the system, as well as on the system as a whole, is evaluated using the Steam System Modeler Tool. This paper elaborates some of the identified measures that are considered more reliable from an operational and financial aspect, mainly focused on steam production for the district heating system. Based on a conservative approach, significant potential for savings of natural gas, electrical energy, and treated water is estimated, which will lead to annual financial savings of about 245000 Euro.
KEYWORDS
PAPER SUBMITTED: 2020-04-03
PAPER REVISED: 2020-05-04
PAPER ACCEPTED: 2020-05-19
PUBLISHED ONLINE: 2020-09-26
DOI REFERENCE: https://doi.org/10.2298/TSCI200403284F
REFERENCES
  1. Turner, W. C., Doty, C., Energy Management Handbook, Sixth Edition, The Fairmont Press, Inc., Lilburn, USA, 2007
  2. European Commission, Reference document on best available techniques for energy efficiency, EC, Sevilla, 2009
  3. UNIDO, Industrial Steam System Optimization (SSO), Experts Training, Training Manual, UNIDO Vienna International Centre, Vienna, Austria, 2012
  4. Group of authors, Steam Conservation Guidelines for Condensate Drainage, Armstrong International, Inc., Steam and Condensate Group, 2016
  5. Kitto, J. B., Stultz, S. C. (editors), Steam, its Generation and Use, 41st edition, Babcock & Wilcox Company, a McDermott company, Barberton, Oh, USA, 2005
  6. Office of Energy Efficiency and Renewable Energy, Improving Steam System Performance: A Sourcebook for Industry, 2nd Edition, US Department of Energy, Washington DC, USA, 2012
  7. Merritt, C., Process steam systems - A practical guide for operators, maintainers and designers, John Wiley & Sons, Inc., 2016
  8. Saidur, R., Energy Savings and Emission Reductions in Industrial Boilers, Thermal Science, 15 (2011), 3, pp. 705-719
  9. Price, T., Majozi, T., Using Process Integration for Steam System Network Optimization with Sustained Boiler Efficiency, Proceedings, 19th European Symposium on Computer Aided Process Engineering - ESCAPE19, June 14-17, Krakow, Poland, 2009
  10. Wu, L., Liu, Y., Liang, X., Kang, L., Multi-objective optimization for design of a steam system with drivers option in process industries, Journal of Cleaner Production, 136 (2016), pp. 89-98
  11. Subiaco, R., Modelling, simulation and optimization perspectives of an industrial steam network, case study at a major oil refinery on the West Coast of Sweden, MSc thesis, University of Pisa, Italy and Chalmers University of Technology, Goteborg, Sweden, 2016
  12. Vučković, G. D., et al.: Avoidable and Unavoidable Exergy Destruction and Exergoeconomic Evaluation of the Thermal Processes in a Real Industrial Plant, Thermal Science, 16 (2012), Suppl. 2, pp. S433-S446
  13. Giacone, E., Manco, S., Energy Efficiency Measurement in Industrial Processes, Energy, 38 (2012), pp. 331-345
  14. Bunse, K., Vodicka, M., Schönsleben, P., Brülhart, M., Ernst F. O., Integrating Energy Efficiency Performance in Production Management Gap Analysis Between Industrial Needs and Scientific Literature. Journal of Cleaner Production, 19 (2011), 6, pp. 667-679
  15. Banjac, M. J., et al.: Introduction of the Energy Management System in the Industrial Sector of the Republic of Serbia, Thermal Science, 22 (2018), Suppl. 5, pp. S1563-S1573
  16. US Department of Energy, Energy Efficiency & Renewable Energy, Steam System Modeler Tool (SSMT), www4.eere.energy.gov/manufacturing/tech_deployment/amo_steam_tool/ (last approach: February 2020)
  17. Babić, M. J., et.al.: Analysis of the Electricity Production Potential in the Case of Retrofit of Steam Turbines in a District Heating Company, Thermal Science, 14 (2010), Suppl., pp. S27-S40
  18. Lazarevska, A. M., Kitanovski, D., Filkoski, R. V., Summary Report for ESA, ELEM Energetika, Steam System Assessment, Skopje, 2016