Installation of TRIGENERATION SYSTEM

Installation of TRIGENERATION SYSTEM 1560 kW

Continental Automotive Romania, Timisoara

The contribution to the powerplant is:  1.393,94 kWp

1.   Introduction

The main activity of Continental Automotive Romania is production of electronic devices and research and development for automotive area.

In 2018, the Company's total electricity consumption was 40500 MWh and total gas consumption was 8800 MWh. In our location is implemented ISO 50001 standard for Energy Management system and the strategy and for increase the efficiency of energy consumption.

The main target is reduction of energy consumption in the main areas of consumption: heating, cooling and circuit board production.

Another target is to assure the continuity of electricity supply due to often disconnections from the city grid.

2.   DEFINITION OF PROJECT No.3_TRIgeneration system

Tri-generation is the process whereby a single fuel source, natural gas (in our case), is used to produce both electrical and thermal energy (cooling and heating).

Remarks:

• Usually fossil-fuelled power plants have an efficiency of 33%. TSR implementation use actively 90% of the gas energy to produce electrical energy and heat & cold

• TSR CHP protect the production lines and critical utilities in case of city line electricity breakdown.

3.   ADVANTAGES

Efficiency Benefits
CHP requires less fuel to produce a given energy output and avoids transmission and distribution losses that occur when electricity travels over power lines. The average efficiency of fossil-fuelled power plants is 30-35 %. Average CHP efficiency is 60-80% some systems could reach 90%.

Environmental Benefits
Because less fuel is burned to produce each unit of energy output and because transmission and distribution losses are avoided, CHP reduces emissions of greenhouse gases and other air pollutants. Usually electricity distribution loss is around 4.5%.

Economic Benefits
CHP can save facilities considerable money on their energy bills due to its high efficiency, and it can provide a hedge against electricity cost increases.

Reliability Benefits
Unreliable electricity service represents a quantifiable business, safety, and health risk for some companies and organizations. CHP is an on-site generation resource and can be designed to support continued operations in the event of a disaster or grid disruption by continuing to provide reliable electricity.

4.    EFFICIENCY ANALYSIS

Gas consumption: before and after TRIGENERATION implemented

5.   DESCRIPTION OF THE TRIGENERATION PROJECTS

The profile of this investment is thermal and electrical energy production in trigeneration, the finished products being: hot water, cool water and electricity. The trigeneration plant are connected to the existing electrical and thermomechanical installations of the company debiting electricity and thermal energy (hot water, cold water) to Continental consumers.

Trigeneration has become an efficient solution for the future for the production of cold water (cold water) in the production areas, offices and warehouses, both in the field of service provision and in the industrial one. During the trigeneration process, the cool water is obtained from the heat energy through a chiller.

Cogeneration on natural gas offers the promise of significant energy savings compared to the traditional technology for producing electricity in thermal power stations on gas or coal. The main economy comes from the local, simultaneous use of electricity and heat. However, thermal energy is not required all year long. The solution is trigeneration: adding an absorption chiller to the cogeneration plants. The absorption chiller uses the heat agent produced by cogeneration to produce cool water with temperatures similar to the ones produced by a classic chiller, considered a conventional technology. By adding a chiller with absorption to the cogeneration group the thermal agent can be used also during the summer, being able to ensure a functioning near 100% of the installation. The use of thermal energy for the production of cool water has many advantages: it allows the continued use of the cogeneration group as a more efficient electricity supply solution than the classical solution; the absorption chiller takes over part of the cooling task of the building, thus reducing the electrical consumption of the classic chillers installed in parallel and thus reducing the load on the overloaded electrical network during the summer.

The methane gas is taken from the methane gas distribution network. By burning it in the gas engine, the electric generator produces electricity. For cooling the gas engine, the chemically treated water delivered from an automatic water treatment station located in the Continental Automotive Romania is used, the hot water thus obtained is delivered to the beneficiary, at a temperature of 90 ° C. The combustion gases discharged from the heat engine are used in a gas-water plate exchanger, with the water outlet temperature also rising to 90 ° C; The circulation of the primary hot water agent is carried out in a closed circuit, the heat transfer being carried out by means of a plate heat exchanger with a capacity of 1700 KW.

With the help of cooling systems, absorber type, part of the hot water is converted into cool water up to 6 ° C. The cooled water is delivered to Continental being used in the production process, to the air conditioning of office and warehouse spaces. In winter, more hot water will be delivered, cool water in summer, the installation allows the combined operation of hot and cold water depending on the CAR needs.

The installation of energy installations are mounted inside containers, a closed enclosure, as follows:

• The internal combustion heat engine driving an electric generator;

• Electric generator with nominal power of 1560 kW;

• The hot water pumping station has 3 pumps, equipped with inverters for automatic adjustment of pump speed depending on the thermal and electrical load:

• Cooling water production facility - 2 absorption chillers, cooling water temperature inlet / outlet: 12/7 ° C.

• Each chiller is equipped with a pumping group consisting of two pumps, which have inverters for automatically adjusting the pump speed depending on the thermal and electrical load, as follows:

• Welded plate heat exchanger;

• Cooling system for internal combustion heat engine and absorption chillers - adiabatic temperature coolers;

• The electrical cabinets that ensure the power supply of these equipment.

6.    ELECTRICAL IMPLEMENTATION

1. CHP power all the production busbars and normally is connected in parallel with city network. The extra generator power is transfer to Conti electrical network using switch K;

2. If city network power down occur the switch is fast disconnected, and generator will power only the production area and some utilities;

3. CHP capacity allow to continue the production in SMT lines and finalize the processes on BE lines.

4. When the city power is restoring automatically the generator is synchronize with the city line and the switch will be close automatically.

7.    POWER INTERRUPTION FROM CITY GRID_COST AVOIDANCE

CHP/generator is connected to production lines busbars and to the mandatory utility (exhaust, compress air, technological water).

1. For PCB production/SMT lines even very short power interrupt create direct scrap (19 lines*20 PCB’s*30 € = 11400 €) and quality risks;

2. All the machines and traceability system after power interruption need to be restart (average 30 minutes production impact);

3. Power interrupt create often damage for production equipment and infrastructure equipment fault;

4. After power interruption, in assemble line all the product in the line need to be check/review at analyze station.

Direct impact: scrap reduction, production efficiency increases and reduce quality risks.

8.    THERMAL CIRCUIT CONNECTION

Cold water:                                              Hot Water:

Production capacity:                                         Production capacity:

CHP: 1.3MW                                                         CHP:1,7 MW

Chillers: 7.3MW                                                    With Burner: 5,8MW

Free cooling (winter): 1,7MW

9. IMPLEMENTATION PHASES

A. Foundation

B. Installation

Fig. Generator in air Fig. Adiabatic chiller

Fig. Inside generator Fig. Electrical installations prepared

1.5 MW engine

Fig. Thermal installations prepared Fig. Thermal installations prepared

Connection to cold circuit

C. Final implementation

Fig. CHP room - thermal installations Fig. CHP room - absorber chillers

Fig. CHP chillers Fig. CHP room- load 100% parallel mode

10. PROJECT TEAM CONTINENTAL AUTOMOTIVE ROMANIA

Dr. Petru Demian

Eng. Petronel Lungu

Eng. Cosmin Vacariuc

Eng. Alexandru Cozmescu

Eng. Ciprian Ceauranu

Eng. Daniel Popescu

11. Contribution to the VPPP

• Energy management 1292 MWh

• Trigeneration: 12.528 MWh energy + 2.907,25 MWh heat

• Total saving: 16.727,25 MWh           

PVPPP= QVE x η / τCS

Where:

PVPPP – Energy Saving accounted in the Virtual Power plant

QVE – The full energy saving, meaning the basis of the calculations

η – average powerplant efficiency

τCS - annual peak hours of the power plant

The contribution to the powerplant is:  1.393,94 kWp

Energy efficiency investments

Energy efficiency investments by installing a cogeneration unit with heat engines and a plant for producing heat by using solar energy, at the Freidorf heating point belonging to the Local District Heating Company Colterm S.A. Timisoara

The contribution to the powerplant is: 155,8 kWp

The Local District Heating Company Colterm SA Timisoara has as object of activity: production, transportation, distribution and supply of heat power; production and sale/supply of electric power.

Initially, one of the 117 heating points, the Freidorf heating point was powered with heat through the primary heating pipe of Colterm SA Timisoara.

Being a long route, for reducing the costs of production and transportation of the heat, the profitability for activity of production and transportation of the heat and the reduction of the emissions, respectively insurance from own sources of electricity power, were analysed several variants of equipping. The solution adopted was the transformation of the Freidorf heating point into the heat station which works on natural gas where the heat for preparation of hot water for consumption to be obtained in cogeneration with heat engines and the heat for warming to be produced with heat only boilers.

In order to accomplish a new efficient source to produce power, located at Freidorf's heating point, the power was charged directly into the distribution electrical network, thus avoiding the transit of electricity through transport networks.

Into the building of Friedorf heating point, were installed the following equipment:

- five heat only boilers type DeDietrich model 525K, with heating power installed 1392-1450 kW

- three heat exchangers with heating plates

- two heat exchangers with heating plates for hot water for consumption

- electric pumps for the movement of the primary and the secondary agent

A cogeneration group with total power (acc. ISO 3046/DIN 6271) of 1.02 MW has been installed to ensure the cogeneration of power and heat generation. It consists of two thermal motors, two electrical generators and heat exchangers needed to take over the heat produced by the engines.

The heat engines work with natural gas and through the electric generators ensures the production of power.

The system is equipped with heat pick-up plants in the engine cooling system and resulting burned gases. The heat taken is used in the primary circuit of the heat station.

The heat recovery system is interconnected with the heat production system. This ensures the functioning of the cogeneration group at the nominal regime during the operation of the heating system. In addition, after commissioning, to increase the efficiency of power, two heat exchangers have been mounted on the plates, on the cooling circuits of the intercooler.

The efficient operation of the cogeneration unit is recorded for a load of engines in margin 50-100%, the load being adjusted according to the demand for heat. Adjusting the task of the group is performed by automatically adjusting the engine load.

The cogeneration unit has the following technical characteristics:

• Electric Power                                 2x 500 = 1000 kW

• Heat Power                                       2x 518 = 1036 kW

• Electrical efficiency                        min. 38.6%

• Total efficiency                                 min. 85.5%

The operating regimes of the cogeneration plant with heat engines are determined according to the demand for heat for warming and preparation of hot water for consumption. Mainly, the CET Freidorf component is the following:

• Circulation pumps 2 x 125 mc/h plus a spare electro pump. The maximum flow rate on the primary circuit is 250 MC/h

• Heat only boilers (1... 5 x 1450 kW) up to 90C

• Three heat exchangers with heating plates

• Two heat exchangers with hot water for consumption plates

• Two heat groups with heat engines connected in series with boilers, with the ceding of heat into the primary system.

• Separating valves that ensure the operation of the primary circuit in the

  • with engines and boilers

  • only with boilers

  • only with engines

The basic regime is considered the winter regime, the period during which the heat requirement is high and therefore the two cogeneration groups work together on the nominal load.

• Power produced per hour                      2 x 501 kWh = 1002 kWh

• Heat produced from

  • Engine Cooling                         2 x 211 kWh = 422 kWh

  • Recovery from flue gases         2 x 307 kWh = 614 kWh

  • Total heat groups                      = 1036 kWh

The additional heat required to cover the consumption is produced in heat only boilers installed in the heating plant.

The heat production system operates at the following parameters:

For periods of passage winter-spring respectively autumn-winter, about two months a year, the heat requirement is given by the needs of hot water for consumption and a reduced need for heating.

The heat production system operates at the following parameters:

Thus, following the energy analyses carried out it was observed that at CET Freidorf, in the year 2018 there were produced: 3,165 MWh Thermal Energy, of which 1,797 MWh in cogeneration, quantity that covered the consumption requirement.

The overall yield of heat and power was 80.1% for the period analysed, and the cogeneration units registered a yield of 80.4%.

Also, in order to streamline the production of heat at CET Freidorf were developed installations that use renewable energy, as an alternative to classical fuels. The renewable energy source accessible in this case was solar energy. This meant the mounting of solar panels, for the production of heat, on the roof of the terrace type of the plant, which would produce, using the existing accumulation tank, heat necessary to prepare hot water for consumption during the summer period for all consumers on CET Freidorf.

The solar-powered hot water production system is composed of solar panel collectors with fluid circulation, which transforms the electromagnetic emission of solar radiation into heat. It is transmitted to a thermic transfer fluid.

The heat transfer from the collectors to the storage tank takes place through forced circulation using a pump operated by a control system.

In the CET Freidorf enclosure a heat exchanger with stainless steel plates, PWT 200 model was installed. It ensures the transfer from solar panels to the accumulation tank. The maximum power of the exchanger is 107 kW and can retrieve the energy from 200 MP solar panel.

The installation located at CET Freidorf has the following technical parameters:

·         Collector are                                                    191,3 m2

·         Total solar fraction                                             48%

·         Annual production in field                                       118.235,1 Kwh

·         Production field surface collector reported gross                618,2 Kwh/m2/an

·         Production collector field relative to Surface                   654,1 Kwh/m2/an

·         Maximum Fuel Economy                                             12.511,7 m3 gas

·         Maximum energy savings                                           131.372,3 Kwh

·         Reduction of CO2 max                                             30.424,3 Kg

The estimated annual heat that can be produced with solar energy is 90 MWh, which implies a reduction in the annual consumption of natural gas of 11800 SMC.

PVPPP= QVE x η / τCS

 Where:

PVPPP – Energy Saving accounted in the Virtual Power plant

QVE – The full energy saving, meaning the basis of the calculations

η – average powerplant efficiency  

τCS - annual peak hours of the power plant

The contribution to the powerplant is: 155,8 kWp

BLEU ELECTRIQUE ROMANIA

BLEU ELECTRIQUE ROMANIA is the subsidiary of a French company olden then 40 years under the brand CCEI Bleu Electrique started the activity in Romania in 2002. Our company is creating and manufacturing equipment for public and private pools.

We offer a wide range of smart devices for professionals of pool market in order to facilitate pool management and improve user comfort. We don’t have yet a department for energy metering, because we are a small company, but our company works on several levels in order to be more energy efficient.

Significant investments have been made in recent years to enlarge with 35% the space of construction, to modernize the building and assure the safety of the workers.

The efficiency of energy consumption is obvious.

Even if the consumers increased proportionally with the extended area, the consumption of energy is almost same like before the extension itself.

We made:

Investments in buildings and equipment

Illumination spots have been fitted to reduce artificial lighting in offices and in the space from production

A large part of the lighting installations has been replaced with economical LED installations.

Also, an automated irrigation system has been implemented

Before:

And after:

The investment regarding the building improvement was around 350.000 euro

Investments on production lines:

Some of technological equipment was replaced with new, energy efficient equipment, with low energy consume.

The implementation of the new production lines led to the diminution of the used electrical equipment.

Investments in our products

The technical team and the management of the company collaborate in order to develop equipment for swimming pools products that fully satisfy the customers in order to reduce the consumption of electricity.

Every year we produce several tens of thousands of devices.

We are constantly looking for innovative products and regularly we make new products to improve light efficiency and their lifetime.

RGBW invests in the lighting market.

For several years, we produce lighting for pool with LED bulbs, cheaper and more resistant than incandescent bulbs that offer unmatched performance with a life of tens of thousands of hours.

The color produced is improved. These are purer, more natural very useful for lighting the garden, a true source of visual comfort and calm.

Another important point is that this technology is still energy efficient: we get the same brightness with less watts consume.I

n the future we will designate an energy manager, responsible with energy efficiency improvements.