HAYAT TISSUE HAYAT TISSUE DRYING PROCESS WITHDRYING PROCESS WITH

GAS TURBINE COGENARATION GAS TURBINE COGENARATION

AHMET IŞIKLARAHMET IŞIKLARMECH.ENG.M.S.MECH.ENG.M.S.

28/09/1028/09/10

PLANT WIEWPLANT WIEW

PATENTPATENTuu Pub. No.:Pub. No.: WO/2008/149249WO/2008/149249 International Application International Application

No.:No.: PCT/IB2008/051542Publication PCT/IB2008/051542Publication Date:11.12.2008International Filing Date:22.04.2008Chapter 2 Date:11.12.2008International Filing Date:22.04.2008Chapter 2 Demand Filed:Demand Filed: 04.12.200804.12.2008

uu IPC:IPC:D21F 5/20D21F 5/20 (2006.01), (2006.01), D21F 11/14D21F 11/14 (2006.01)(2006.01)Applicants:HAYAT Applicants:HAYAT KIMYA SANAYI ANONIM SIRKETIKIMYA SANAYI ANONIM SIRKETI [TR/TR]; Mahir Iz Caddesi No:23 [TR/TR]; Mahir Iz Caddesi No:23 Altunizade, Uskudar, 34662 Istanbul (TR) Altunizade, Uskudar, 34662 Istanbul (TR) (All Except US)(All Except US)..ISIKLAR, Ahmet NezirISIKLAR, Ahmet Nezir [TR/TR]; (TR) [TR/TR]; (TR) (US Only)(US Only)..Inventor:ISIKLAR, Inventor:ISIKLAR, Ahmet NezirAhmet Nezir; (TR).; (TR).Agent:ANKARA PATENT BUREAU LIMITEDAgent:ANKARA PATENT BUREAU LIMITED; ; Bestekar Sokak No.10, Kavaklidere, 06680 Ankara (TR) Bestekar Sokak No.10, Kavaklidere, 06680 Ankara (TR) ..PriorityPriority Data:Data:2007/038162007/03816 04.06.200704.06.2007 TRTRTitle:Title:A COGENERATION A COGENERATION APPLICATION IN PRODUCING SANITARY PAPER APPLICATION IN PRODUCING SANITARY PAPER Abstract:Abstract:The objective of The objective of the present invention is to realize a sanitary paper production method the present invention is to realize a sanitary paper production method which eliminates problems that originate from the mains power supply and which eliminates problems that originate from the mains power supply and cause disruption in production, while enabling energy conservation in cause disruption in production, while enabling energy conservation in sanitary paper production. For this purpose, a sanitary paper production sanitary paper production. For this purpose, a sanitary paper production method is realized wherein electricity is produced from combustion gases method is realized wherein electricity is produced from combustion gases by means of a turbine (1), the hot combustion gases emanating from the by means of a turbine (1), the hot combustion gases emanating from the turbine are utilized by being used in drying (3) of sanitary paper and the turbine are utilized by being used in drying (3) of sanitary paper and the gases emanating from sanitary paper drying process are cooled with an gases emanating from sanitary paper drying process are cooled with an absorption chiller(5), and thus a solution has been provided to the absorption chiller(5), and thus a solution has been provided to the problem.problem.

22 stockstock prepprep lineslines((22)) layerslayers hdbxhdbx withwith consistencyconsistency profilingprofilingCrescentCrescent formerformer tissuetissue machinemachineCombiningCombining withwith ((44)) unwindunwind stationsstationsProductionProduction (average)(average):: 200200 tons/dtons/dDetailedDetailed engineeringengineering --StartedStarted upup 1717 JanuaryJanuary 20062006

LAY-OUT

COGEN UNİTCOGEN UNİT

COGEN UNIT SECTIONCOGEN UNIT SECTION

uu UTILIZING OF THE EXHAUST GASES FROM GAS TURBINES UTILIZING OF THE EXHAUST GASES FROM GAS TURBINES INCREASED THE TOTAL EFFICIENCY AND EXERGYINCREASED THE TOTAL EFFICIENCY AND EXERGY

uu (AVAILABITY=EXERGY= (AVAILABITY=EXERGY= uu ENERGY QUANTITYxENERGY QUALITY)ENERGY QUANTITYxENERGY QUALITY)uu ENERGY IS EFFICIENTLY USED WHEN THE QUALITY OF THE ENERGY IS EFFICIENTLY USED WHEN THE QUALITY OF THE

SOURCE IS MATCHED TO THE QUALITY DEMANDED BY SOURCE IS MATCHED TO THE QUALITY DEMANDED BY TASK.THUS ELECTRICITY IS A THERMODINAMICALLY SOUND WAY TASK.THUS ELECTRICITY IS A THERMODINAMICALLY SOUND WAY TO DRIVE THE MOTOR THAT AGITATES THE CLOTHES IN THE TO DRIVE THE MOTOR THAT AGITATES THE CLOTHES IN THE WASHING MACHINE.IT IS NOT SOUND WAY TO HEAT UP THE WASHING MACHINE.IT IS NOT SOUND WAY TO HEAT UP THE WASHING WATER.BY THERMODINAMICALLY MATCHING SOURCES WASHING WATER.BY THERMODINAMICALLY MATCHING SOURCES TO TASKS,WE CAN AVOID THE USING HIGH QUALITY ENERGY TO TASKS,WE CAN AVOID THE USING HIGH QUALITY ENERGY FOR LOW QUALITY TASKS.FOR LOW QUALITY TASKS.

CogenCogen

CHANGECHANGE

NEW TYPE COGENNEW TYPE COGEN

MAIN IRREVERSIBILITIES IN BOTH MAIN IRREVERSIBILITIES IN BOTH INSTALLATIONS ARE IN THE COMBUSTION INSTALLATIONS ARE IN THE COMBUSTION PROCESS AND IN THE EXERGY OF THE PROCESS AND IN THE EXERGY OF THE WASTE GASES OF THE TURBINE INTO THE WASTE GASES OF THE TURBINE INTO THE HOOD THEN INTO THE WASTEHOOD THEN INTO THE WASTE--HEAT HEAT BOILERS FOR THE STEAM GENERATION.BOILERS FOR THE STEAM GENERATION.

uu EXHAUST GASES FROM GAS TURBINE EXHAUST GASES FROM GAS TURBINE CONCEQUENTLY USED IN THE HOOD, BOILERS CONCEQUENTLY USED IN THE HOOD, BOILERS AND ABSORBTION CHILLER.AND ABSORBTION CHILLER.

uu HOT EXHAUST GASES ACT TO THE SURFACE OF HOT EXHAUST GASES ACT TO THE SURFACE OF THE PAPER BY CONVECTION AND CYLINDER THE PAPER BY CONVECTION AND CYLINDER HEATED FROM INSIDE BY STEAM AS HEATED FROM INSIDE BY STEAM AS CONDUCTION.BY THIS WAY WATER INSIDE OF THE CONDUCTION.BY THIS WAY WATER INSIDE OF THE PAPER EVOPORATED.PAPER EVOPORATED.

uu CONVENTIONAL SYSTEM NEED TO HUMIDITY CONVENTIONAL SYSTEM NEED TO HUMIDITY CONTROL, BUT COGEN SYSTEM IS NOT.CONTROL, BUT COGEN SYSTEM IS NOT.

INCREASE OF ELECTRICAL INCREASE OF ELECTRICAL PRODUCTIONPRODUCTION

USE OF COGENERATION GASESCONVENTIONAL HOOD

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

Cogeneration gases flow (ton/h)

Elec

trica

l pow

er c

onsu

mpt

ion

(kW

)

0,100

0,125

0,150

0,175

0,200

0,225

0,250

0,275

0,300

0,325

0,350

0,375

0,400

0,425

0,450

0,475

0,500

0,525

0,550

Wat

er c

onte

nt a

r hoo

d ex

haus

t (k

hH2O

/kgd

a)

FIRST PRINCIPLE OF ANALYSIS:• Reduction of hood heater consumption:

Interest in improving efficiencies and reducing consumption

USE OF COGENERATION GASESCONVENTIONAL HOOD

0

100

200

300

400

500

600

700

800

900

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

Waste gases flow (ton/ h)

0,1000,1250,1500,1750,2000,2250,2500,2750,3000,3250,3500,3750,4000,4250,4500,4750,5000,5250,550

uu COGENERATION CONSISTING WITH THE 7 COGENERATION CONSISTING WITH THE 7 MAIN ITEMSMAIN ITEMS

1.1. TWO GAS TURBINE EACH 7,5 MEGAWATT . TWO GAS TURBINE EACH 7,5 MEGAWATT . 2.2. DRYING HOODS DRYING HOODS 3.3. 2 STEAM BOILER ( 16 BARG )+2 STEAM 2 STEAM BOILER ( 16 BARG )+2 STEAM

BOILER (3 BARG) BOILER (3 BARG) 4.4. 2 DUCT TYPE BURNER2 DUCT TYPE BURNER5.5. ABSORBSTION CHILLERABSORBSTION CHILLER6.6. FANS AND DAMPERSFANS AND DAMPERS7.7. AUTOMATIONAUTOMATION

uu ADVANTAGESADVANTAGES

11-- ENERGY SAVING OBTAINED IN THIS SYSTEM ENERGY SAVING OBTAINED IN THIS SYSTEM CONTRARY TO THE CONVENTIONAL SYSTEM.CONTRARY TO THE CONVENTIONAL SYSTEM.

22-- EXHAUST GASES UTILIZES FOR THE EXHAUST GASES UTILIZES FOR THE FOLLOWING SERVICES: PAPER DRYING , FOLLOWING SERVICES: PAPER DRYING , STEAM PRODUCTION AND CHILLED WATER STEAM PRODUCTION AND CHILLED WATER PRODUCTION PRODUCTION

uu CALCULATIONCALCULATIONYANKEE DIA = 5486 MMYANKEE DIA = 5486 MMYANKEE PAPER WITDH = 5600 MMYANKEE PAPER WITDH = 5600 MMYANKEE SPEED = 2000 M/MINYANKEE SPEED = 2000 M/MINYANKEE PRODUCTION = 7321 KG/HYANKEE PRODUCTION = 7321 KG/HCREP RATIO = %16CREP RATIO = %16PAPER GRAMMAGE = 13 PAPER GRAMMAGE = 13 –– 16 16 –– 21 GR/M221 GR/M2

ELEKTRICAL ENERGY PRODUCTIONELEKTRICAL ENERGY PRODUCTIONuu TURBINE EFFICIENCY IS %33,7TURBINE EFFICIENCY IS %33,7

uu TW0 GAS TURBINE EACH ONE PRODUCED TW0 GAS TURBINE EACH ONE PRODUCED 7.315 KW ELECTRICAL ENERGY AT 15 C 7.315 KW ELECTRICAL ENERGY AT 15 C AMBIENT AIR TEMPERATURE.AMBIENT AIR TEMPERATURE.

EFFICIENCY COMPARISONEFFICIENCY COMPARISON

AA-- ENERGY EFFICIENCYENERGY EFFICIENCYPARAMETERS ( CONVANTIONEL SYSTEM )PARAMETERS ( CONVANTIONEL SYSTEM )

ηη drying = drying = M steam.hood. x hfg M steam.hood. x hfg M fuel x LHVM fuel x LHV

ηη drying = drying = 7171 kw7171 kw = % 68= % 6810526 kw10526 kw

BB-- ENERGY EFFICIENCYENERGY EFFICIENCYPARAMETERS ( COGENERATION SYSTEM)PARAMETERS ( COGENERATION SYSTEM)

ηη (DRYING +GENERATOR + BOILER) = (DRYING +GENERATOR + BOILER) =

= = Mste.hood.xhfg + Wxnet +Msteamxhfg Mste.hood.xhfg + Wxnet +Msteamxhfg M fuel x LHVM fuel x LHV

= = 7171 kw +2x7315kw + 2x6800kw7171 kw +2x7315kw + 2x6800kw = % 74= % 743650 kw + 2x22110 kw3650 kw + 2x22110 kw

CC-- ENERGY EFFICIENCYENERGY EFFICIENCYPARAMETERS ( COGENERATION SYSTEM+ PARAMETERS ( COGENERATION SYSTEM+ ABSORBTION CHILLER)ABSORBTION CHILLER)

ηη ( tissue drying +genarator +boiler+abs.chiller)= ( tissue drying +genarator +boiler+abs.chiller)=

= = Mstm.hood.xhfg + Wxnet + Mstmxhfg +Mabsxhfg Mstm.hood.xhfg + Wxnet + Mstmxhfg +Mabsxhfg Mfuel x LHVMfuel x LHV

= = 7171 kw +2x7315kw + 2x6800kw +2x4650kw7171 kw +2x7315kw + 2x6800kw +2x4650kw3650 kw + 2x22110 kw3650 kw + 2x22110 kw

= % 93= % 93

COGENERATION SYSTEM, CONTROLLED WITH COGENERATION SYSTEM, CONTROLLED WITH THE FOLLOWING EQUIPMENT AND THE FOLLOWING EQUIPMENT AND AUTOMATION.AUTOMATION.

11-- INTEGRATED ELECTRICAL AND THERMAL INTEGRATED ELECTRICAL AND THERMAL SYSTEMSYSTEM

22-- EXHAUST GAS PRESSURE CONTROLEXHAUST GAS PRESSURE CONTROL33-- HOOD BALANCE CONTROLHOOD BALANCE CONTROL44-- TEMPERATURE CONTROLTEMPERATURE CONTROL55-- FANS FANS ΔΔP CONTROLP CONTROL66-- BYBY--PASS SYSTEMPASS SYSTEM77-- BOILER PRESSURE CONTROLBOILER PRESSURE CONTROL

CONCLUSIONCONCLUSION

uuHAYAT TISSUE PLANT USED DRYING HAYAT TISSUE PLANT USED DRYING WITH THE GAS TURBINE EXHAUST WITH THE GAS TURBINE EXHAUST COGENERATION HAS BEEN COGENERATION HAS BEEN SUCCEEDED INSPITE OF THE FIRST SUCCEEDED INSPITE OF THE FIRST APPLICATION IN THE WORLDAPPLICATION IN THE WORLD

CONVENTIONAL AND CONVENTIONAL AND COGENERATION SYSTEM COMPARISONCOGENERATION SYSTEM COMPARISON

Air System Std. CogenType Duocascade DuoparellelRecirculation 80% 0%-20%Exhaust air flow 20% 80-100%Exhaust air temperature 200 C (After heat recovery 380 C (No heat recovery)Exhaust air humidity 400-500 gr/kg 100-200 gr/kgExhaust air thermal power Low HighImpıngment air flow Same Same or lowerImpingment air temp. 510 C 510 CImpingment air humidity 200-400 gr/kg 50-100 gr/kgMake up air flow 10 % 80-100 %Make up air temperature 200-280 C 450-550 CMake up air humidity 10 gr/kg 50 gr/kgProcess temperature 330-380 C 450-510 C