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Master Programme in Energy Systems
Examiner: Ulf Larsson
Supervisor: ke Bjrnwall
Preface
This investigation, as final Thesis Project of Master in Energy Systems
(University of Gvle), was started to carry out in February, in collaboration with
the company Gvle Energi AB. Many people have been involved answering my
questions, providing me with information and so forth; some of those are
mentioned below.
Secondly, I would like to thank the rest of workers at Gvle Energi AB,
who have done everything they can to help me, in addition to make pleasant my
stay in the company.
I would also like to thank Ulf Larsson at the University of Gvle for his
help. Furthermore, I am very grateful for all information I have received from
other companies.
Abstract
Gvle Energi AB is a company which produces electricity as well as heat
that is delivered through a district heating network in the municipality of Gvle.
Apart from that, as cooling demand is large when seen from a global perspective,
at present it is building a district cooling network based on refrigerant compressor
technology with the idea of replacing less efficient individual HVAC systems in
the city center.
High electricity prices lead to reduce its use as far as possible, so it is also
needed to consider absorption systems as cooling technology. This way, the main
aim of this thesis is to analyze possible benefits with the use of heat driven
absorption chillers compared with conventional vapour compressor chillers.
For carrying out this investigation, first of all background and literature
study have been essential. As a result, information about cooling technologies,
district energy and cogeneration plants is gathered in this work.
The research is focused on three areas of the victinity of Gvle: city center,
Kungsbck and Johannesbergsvgen.
In the first area, Gvle Energi AB might take the opportunity of using a
new ORC plant in biomass based cogeneration system that Bionr is planning to
build at LEAF, turning it into a trigeneration plant. So how bigger the installation
should be (according to the expected cooling demand that has been calculated in
the earliest steps) and the profits related to extra electricity production are
estimated in this study, in addition to examine the absorption chillers to be
introduced and their operational conditions.
that extra steam might be produced to fire absorption chillers and fulfil the
cooling demand of the
hospital (Gvle
Sjukhus),
technological park
(Teknikparken) and university (Hgskolan i Gvle), which are located in this area.
Like this, the same methodology as for LEAF has been followed for making
decisions.
Table 0. Costs of absorption cooling installations, extra heat to be produced for the
absorption chillers and extra electricity output in the three studied sites
PRODUCTION
OPERATIONAL
HEATING
ELECTRICITY
SITE &TOTAL
INVESTMENT
COSTS
DEMAND
PRODUCTION
COOLING
COST [SEK]
[SEK/year]
[MWh/year]
[MWh/year]
LOAD
LEAF
22 627 000
4 753 485
17 977
4 135
21 385 MWh/year
MACKMYRA
17 700 000
2 504 835
7 819
1 173
9 298 MWh/year
JOHANNES
8 800 000
3 561 396
10 460
3 033
8 496 MWh/year
Lastly, it has been come to the conclusion that a sustainable energy system
for Gvle for fulfilling the cooling demand can be the erection of district cooling
networks with trigeneration plants by producing cooling in heat driven absorption
cooling machines. Despite larger investment cost of absorption systems compared
to compression ones, total costs after roughly five years are lower. Moreover,
electric coefficient of performance is about 23% higher for the absorption cooling
technology and there is a great electricity output too, which makes possible to
reduce electrical loads, to use the biofuel in an effective way and, last but not
least, to decrease global carbon dioxide emissions.
TABLE OF CONTENTS
CHAPTER 1. INTRODUCTION ..................................................................... 1
1.1. BACKGROUND ....................................................................................... 2
1.1.1. COOLING AND ITS PRODUCTION .................................................................... 2
1.1.2. GVLE ENERGI AB AND ITS PLANS FOR THE FUTURE................................ 3
TABLE OF CONTENTS
II
TABLE OF CONTENTS
REFERENCES ................................................................................................. 88
APPENDICES .................................................................................................. 92
Appendix 1. PLANNED REFRIGERANT COMPRESSION
INSTALLATION ................................................................ 93
A1.1. INSTALLATION ................................................... 93
A1.2. COOLING LOAD ................................................. 99
A1.3. INPUT LOAD AND COSTS ................................ 100
A1.4. TOTAL COSTS ................................................... 102
A1.5. PAY-BACK TIME FOR THE INVESTMENTS... 103
Appendix 2. EXPECTED COOLING DEMAND ................................ 104
III
TABLE OF CONTENTS
IV
LIST OF FIGURES
Figure 1. Refrigerant compression cycle ........................................................... 10
Figure 2. Temperature-Entropy (T-s) diagram for a Vapour-Compression
Refrigeration Cycle ........................................................................... 11
Figure 3. Scheme of basic absorption cycle ....................................................... 14
Figure 4. Schematic of the fundamental absorption refrigeration system ........... 17
Figure 5. Ammonia/Water absorption cycle ...................................................... 20
Figure 6. Crystallization temperatures of water/lithium bromide solution
against the mass concentration of lithium bromide ............................. 21
Figure 7. Maximum system pressures against the condenser temperature .......... 22
Figure 8. Minimum system pressures against the evaporator temperature ......... 23
Figure 9. COP of the absorption systems against the condenser temperature
(heat exchanger efficiency 0,6) .......................................................... 24
Figure 10. COP of the absorption systems against the generator temperature
(heat exchanger efficiency 0,6) ........................................................ 24
Figure 11. COP of the absorption systems against the evaporator temperature
(heat exchanger efficiency 0,6) ........................................................ 25
Figure 12. Cooling cycle schematic .................................................................. 27
Figure 13. Double-Effect Water/Lithium Bromide Absorption Chiller
Schematic ....................................................................................... 28
Figure 14. Sketch for a double effect absorption heat pump in a log pressuretemperature diagram ........................................................................ 29
Figure 15. Comparison between compression and absorption technologies
using ammonia as refrigerant and cooling water with a temperature
of 25 C ........................................................................................... 31
Figure 16. Components of district cooling systems ........................................... 36
Figure 17. District cooling system (or district heating system) .......................... 36
Figure 18. An schematic of cogeneration process that shows the consumed
and produced power in the whole system ........................................ 37
Figure 19. Illustration of a CHP plant connected to a district heating network ... 38
Figure 20. Energy efficiency of ORC units in cogeneration applications ............ 43
Figure 21. ORC plant in biomass based cogeneration system ............................. 43
Figure 22. Johannes CHP plant before 2003 ...................................................... 44
Figure 23. Production of heat (for District Heating) and electricity at
Johannes .......................................................................................... 45
Figure 24. Existing electric boiler in Mackmyra ................................................ 46
Figure 25. Existing and planned boilers at Mackmyra ........................................ 47
Figure 26. Three cooling production and customer sites and main pipes ............ 49
Figure 27. Cooling power to be produced in different sites during the year ........ 53
Figure 28. Typical piping diagram of an absorption system ............................... 56
Figure 29. Graph that shows the breakdown of total costs for 10 years at
LEAF ............................................................................................... 60
LIST OF FIGURES
Figure 30. Graph that shows the breakdown of total costs for 10 years in
Mackmyra production site ................................................................ 63
Figure 31. Graph that shows the breakdown of total costs for 10 years in
Johannes production site .................................................................. 66
Figure 32. Comparison of cooling installations with absorption and
compression machines at LEAF ....................................................... 74
Figure 33. Increased heat load for the three absorption plants and the possible
extra electricity that would be produced ........................................... 79
Figure 34. Increased heat and electricity load in the probable Johannes
trigeneration plant ............................................................................ 79
Figure 35. Required operational conditions of the boiler for the cooling plant at
Johannes .......................................................................................... 80
Figure 36. Comparison of total costs for ten years for the different cooling
production technologies at LEAF ..................................................... 81
Figure 37. Electricity production and consumption according to the cooling
demand in three different scenarios .................................................. 84
Figure 38. Costs and profits (due to electricity production) according to the
cooling demand in three different scenarios ...................................... 84
Figure A1. 1. Draft of the whole compression installation.................................. 90
Figure A1. 2. Draft of the devices of the compression installation...................... 90
Figure A1. 3. Maintenance costs in the course of time ....................................... 99
Figure A3. 1. Water streams (steam and DH) at Johannes CHP plant ............... 111
Figure A3. 2. Cooling demand load curve (2008) divided in periods
according to the power needed to be produced ........................... 116
Figure A4. 1. Map of the city center with the main pipe that leaves LEAF
production site and its length ..................................................... 130
Figure A4. 2. Map with the customers, pipes and distances for Mackmyra
production site ........................................................................... 132
Figure A4. 3. Map with the customers for Johannes production site, pipe and
its length .................................................................................... 134
Figure A4. 4. Map of the shopping centers under construction in Hemlingby ... 135
Figure A4. 5. Map of the future residential area close to Johannes plant .......... 136
Figure A5. 1. SBI monogram showing the parameters of the different pipes .... 140
Figure A5. 2. Differential pressures in a direct return distribution system with
one terminal unit ........................................................................ 141
Figure A5. 3. Piping excavation section ........................................................... 143
Figure A5. 4. Distribution system cost split up in its components and their
contribution to the total cost....................................................... 145
Figure A6. 1. Draft of the whole cooling installation in Falun .......................... 147
Figure A7. 1. Scheme of Johannes CHP plant .................................................. 150
Figure A7. 2. Fuel storage and conveyor belt carrying biofuel to the boiler at
Johannes .................................................................................... 151
Figure A7. 3. Bubble Fluidized Bed (BFB) boiler of Johannes CHP plant ....... 152
VI
LIST OF FIGURES
Figure A7. 4. Illustrative drawing of Olga turbine and components .................. 153
Figure A7. 5. Olga turbine on the left side and heat exchangers on the right
Side. Johannes CHP plant .......................................................... 153
Figure A7. 6. Schematic of the FGC at Johannes ............................................. 154
Figure A7. 7. Detailed scheme of the condensate treatment plant at Johannes .. 154
VII
LIST OF TABLES
Table 1. Production sites and customers ............................................................ 4
Table 2. Absorption working fluids properties ................................................ 23
Table 3. Comparison of parallel and series flow for double-effect water/lithium
bromide cycles .................................................................................... 29
Table 4. Energy saving with cogeneration for = 0,54 ..................................... 33
Table 5. Summary of characteristics for cooling options .................................. 34
Table 6. Comparison between two 1000kW chillers ......................................... 34
Table 7. Different types of plants using a steam boiler and their
characteristics ..................................................................................... 38
Table 8. Cooling load demand at each site ....................................................... 50
Table 9. Possibilities to fulfill the cooling demand in the city center by using
steam-fired absorption chillers ............................................................ 51
Table 10. Possibilities to fulfill the cooling demand in Kungsbck by using
steam-fired absorption chillers ........................................................... 52
Table 11. Possibilities to fulfill the cooling demand corresponding to Johannes
plant ................................................................................................. 54
Table 12. Cooling that should be produced for different sites during the year .... 55
Table 13. Power and steam demand of different chillers sets for the required
cooling load at LEAF during the year ................................................ 57
Table 14. Biofuel (for producing steam), electricity and water consumption.
LEAF ................................................................................................ 58
Table 15. Investment costs [SEK] for LEAF ..................................................... 58
Table 16. Operational costs at LEAF ................................................................ 59
Table 17. Total costs of LEAF absorption cooling plants for 10 years ............... 59
Table 18. Power and steam demand of different chillers sets for the required
cooling load in Mackmyra production during the year ....................... 61
Table 19. Biofuel (for producing steam), electricity and water consumption.
Mackmyra ......................................................................................... 61
Table 20. Investment costs [SEK] for Mackmyra .............................................. 62
Table 21. Operational costs in Mackmyra production site ................................. 62
Table 22. Total costs of Mackmyra absorption cooling plants for 10 years ........ 63
Table 23. Power and hot water demand of chillers set for the required cooling
load at Johannes during the year ........................................................ 64
Table 24. Biofuel (for producing steam), electricity and water consumption.
Johannes ............................................................................................ 64
Table 25. Investment costs [SEK] for Johannes................................................. 65
Table 26. Operational costs in Johannes production site .................................... 65
Table 27. Total costs of Johannes absorption cooling plant for 10 years ............ 65
Table 28. Operational conditions of different chillers sets at LEAF during
the year when the cooling demand is 10% higher than the estimated
one .................................................................................................... 67
VIII
LIST OF TABLES
Table 29. Total costs of LEAF absorption cooling plants for 10 years when the
cooling demand is 10% higher than the estimated one ....................... 67
Table 30. Operational conditions of different chillers sets at LEAF during the
year when the cooling demand is 10% lower than the estimated one .. 68
Table 31. Total costs of LEAF absorption cooling plants for 10 years when the
cooling demand is 10% lower than the estimated one ........................ 68
Table 32. Operational conditions of different chillers sets in Mackmyra
production site during the year when the cooling demand is 10%
higher than the estimated one ............................................................ 69
Table 33. Total costs of Mackmyra absorption cooling plants for 10 years
when the cooling demand is 10% higher than the estimated one ........ 69
Table 34. Operational conditions of different chillers sets in Mackmyra
production site during the year when the cooling demand is 10%
lower than the estimated one.............................................................. 70
Table 35. Total costs of Mackmyra absorption cooling plants for 10 years
when the cooling demand is 10% lower than the estimated one ......... 70
Table 36. Operational conditions of different chillers sets in Johannes
production site during the year when the cooling demand is 10%
higher than the estimated one ............................................................ 71
Table 37. Total costs of Johannes absorption cooling plants for 10 years when
the cooling demand is 10% higher than the estimated one .................. 71
Table 38. Operational conditions of different chillers sets in Johannes
production site during the year when the cooling demand is 10%
lower than the estimated one.............................................................. 71
Table 39. Total costs of Johannes absorption cooling plants for 10 years when
the cooling demand is 10% lower than the estimated one ................... 71
Table 40. Operational conditions of the existing cooling project but with
absorption machines .......................................................................... 73
Table 41. Power and steam demand of chillers set for the required cooling load
in the existing cooling project but with absorption machines ............. 73
Table 42. Operational costs in the existing cooling project but with absorption
machines ........................................................................................... 73
Table 43. Total costs of the existing cooling project but with absorption
machines for 10 years ........................................................................ 73
Table 44. Data about the distribution systems ................................................... 75
Table 45. Cost of the distribution systems ......................................................... 75
Table 46. Operational conditions and costs of distribution pumps ..................... 75
Table 47. Most adequate chillers and costs & profits for the three production
sites ..................................................................................................... 78
Table 48. Annual benefits of absorption cooling technology at LEAF after 10
years .................................................................................................... 81
IX
LIST OF TABLES
LIST OF TABLES
LIST OF TABLES
XII
CHAPTER 1
Introduction
This chapter is a definition of the thesis, which describes the issues to be
studied and the reasons for their investigation, as well as the main purpose, scope,
limitations and so forth.
1.1. BACKGROUND
1.1.1. COOLING AND ITS PRODUCTION
It is a fact that cooling demand is as high as or even higher than heating
demand, since it is needed for both thermal comfort and many industrial processes
and, in addition, it is required more energy for producing cooling than heating.
Hence, production of cold could be very profitable for energy companies when it
is a part of the existing energy system.
Chapter 1. INTRODUCTION
energy carrier when it is used for non-electricity specific purposes. To reach this
target, the choice of absorption facilities as cooling technology is clear.
Gvle Energi AB not only ensures short-term goals but it has always longterm objectives to contribute actively to the Gvle region's development. Thus, as
cooling demand is large when seen from a global perspective, it is building a
district cooling network which will be finished in a near future. In a first step, the
planned production of cold is based on refrigerant compressor technology and at
present, it is thinking of future possibilities of using absorption cooling systems
because of its low operational costs.
This way, the company wants to study the construction of district cooling
systems by absorption cooling facilities for three small islands as large customers:
city center, Hemlingby shopping centers and, finally, Kungsbck area (university,
hospital and technological park as a whole). Power for producing cold for these
Chapter 1. INTRODUCTION
SITE
NEARBY LARGE
CUSTOMER
1.2. PURPOSE
The aim of this thesis is to study economic and technological aspects of
absorption cooling in the three cases already presented (see Table 1.). Therefore,
it is required to decide needed size of installations in order to analyze costs and
profits.
1.3. SCOPE
A district cooling system consists of three primary components: central
plant (production), distribution system and customer system (market). The first
two will be studied, starting from technological aspects and going through
economic ones after.
Chapter 1. INTRODUCTION
1.4. LIMITATIONS
Even though more aspects ought to be taken into account, the matters
mentioned in the scope are at focus and neither investment costs of steam boilers
nor costs regarding customer substations should be considered. On the one hand,
boilers either already exist or will be built anyway (this way, operational costs of
producing steam for absorption chillers are also not pondered because boilers are
working anyway and extra costs are negligible). On the other hand, it is very
difficult to estimate the cost of customer facilities and furthermore, they will be
the same whichever way the cold is produced (the main aim is to compare cooling
production systems).
1.5. METHOD
First of all, the issues of the thesis and reasons why they are interesting to
investigate have been analyzed. In this way, the project has been specified and
tasks for carrying it out have been defined in depth. Afterwards, a literature study
Chapter 1. INTRODUCTION
has been done to get enough knowledge about subjects: cooling technologies,
district cooling systems and CHP plants using biofueled steam boilers.
Secondly, in the projects early stages, it has been got in touch with
consultants of Gvle Energi AB and experts at absorption cooling (Ramboll) and
refrigerant compressor (SWECO) technologies for gathering together information
about real installations and equipments in the market, as well as for examining
them from different points of view.
Once different parts have been understood, it has been gone ahead with the
thesis by concentrating on the real cases the investigation had to be focused on.
Like this, it has been asked for data about customers cooling demand (load
required), distribution distances and so on to make a first estimation of needed
size of the installations and thus, the operational conditions.
The next step has been to decide on production plant size, for later weigh
costs up. This has let profits of the new technology be known as regards extra
electricity production and use of steam for cooling production. And, to finish with
the production part, the compression installation has been compared with
absorption one and, in addition, a sensitivity analysis, which ranges over size of
equipments, costs and profits, has been done.
Last but not least, decisions regarding distribution systems have been
made and costs has been also assessed.
Chapter 1. INTRODUCTION
Chapter 4 studies thoroughly the real cases. This way, firstly it is presented
the current situation and future plans (Section 4.1.). Thereafter, it is explained
how decisions about production sites and customer areas have been made, in
addition to sum up collected data about cooling demands and estimations about
distances (Section 4.2.). Finally, data researchs and analysis regarding absorption
cooling plants are included (Section 4.3.).
CHAPTER 2
10
11
Nowadays, the most usual refrigerants are ammonia (NH3) and R134A
(CHF2CHF2).
a.
Selection of refrigerant
12
13
14
pressure of refrigerant in the evaporator. Vapour pressure of solution absorbentrefrigerant in the absorber determines the pressure in low-pressure side of the
system and accordingly, refrigerants evaporating temperature. In turn, vapour
pressure of solution absorbent-refrigerant depends on absorbers nature,
temperature and concentration. The lower the temperature of absorbent is and, in
addition, the higher its concentration is, the pressure in the solution will be lower.
According to all this, since the absorber is in the low pressure side of the
system and the generator in the high pressure one, the strong solution must be
pumped from the absorber to the generator and the weak solution must be
returned through a pressure reducing valve or restrictor to the absorber.
Refrigerant is not compressed in the process of increasing its pressure, since it has
to take place in the absorber. Consequently, power required by the pump is
relatively small.
15
The next stage is to study whether efficiency can be improved even more.
This can be achieved by introducing a heat exchanger between the strong
solution that goes to the generator and the weak solution (with high
temperature) that returns from the generator to the absorber. As temperature of the
solution that goes to the generator is increased, whereas it is decreased in that
which goes to the absorber, it is needed to supply the generator with less heat as
well as to cool down less in the absorber. [7]
16
2.2.1. CONSIDERATIONS
FOR
DIMENSIONING
ABSORPTION CIRCUITS
It is more difficult to dimension absorption systems than compression
ones. That is due to the fact that they work according to the thermodynamic
balance, which changes depending on environmental conditions. For this reason,
to determine whether instantaneous performance of certain equipments is correct,
17
18
2.2.2.2.AMMONIA/WATER (NH3/H2O)
High volatility of water makes to be necessary the introduction of a
rectifier (reflux condenser) after the generator so that water steam that refrigerant
contains is eliminated before it goes into the condenser. Otherwise, temperature in
the evaporator is increased and consequently, cooling capacity decreases.
Moreover, it may form ice in the evaporator and expansion device.
19
20
maintained units can lead to leak of atmospheric air into them) and the high
viscosity of the solution. On the contrary, it is very safe and has high volatility
ratio, affinity and stability, in addition to high latent heat. [12]
22
MIXTURE
ABSORBENT
REFRIGERANT
Good
Good
Excellent
Poor
Limited application
Good
Good
Good
23
In this way, lets say that water/lithium bromide systems have much less
problems and are simple to operate, although concentration of the mixture has to
be controlled to prevent crystallization. Likewise, its COP (also limited by
crystalization) is higher.
Figure 9. COP of the absorption systems against the condenser temperature (heat exchanger
efficiency 0,6) [12]
Figure 10. COP of the absorption systems against the generator temperature (heat
exchanger efficiency 0,6) [12]
24
Figure 11. COP of the absorption systems against the evaporator temperature (heat
exchanger efficiency 0,6) [12]
The required electricity represents 1-2% of the total cooling effect. With
regards to the heat, depending on how absorption chillers are fired, the system can
be:
25
Indirect-fired system. Fuel is steam or high temperature water that comes from
a separate source such as CHP plants, geothermal, solar or waste heat. This
thesis studies these ones.
Finally, it cannot be left behind that the absorber as well as condenser are
cooled down by a refrigeration tower, which energy consumption has to be
considered. Natural water, such as water from the river, can be used instead of
cooling towers for optimizing overall efficiency of the system.
26
The COP for these chillers is, depending on the model, around 0,7 [13]
(for instance, Carrier 16TJ-41 and 16TJ-42 have a COP of 0,73 and 0,72
respectively).
27
28
Figure 14. Sketch for a double effect absorption heat pump in a log pressure-temperature
diagram [13]
The COP of two stages cycles is in the range of 1,0 to 1,2 [14] (for
instance, Carrier 16NK-53 has a COP of 1,42).
1,325
354,4
1,244
371,1
1,238
370,2
29
Even though a double-effect system needs more devices than a singleeffect one, if a cooling tower is needed as a heat sink, less cooling tower capacity
is needed per unit cooling effect due to the higher COP in a double-effect chiller
[13]. Taking this into account, total system cost may be comparable to a singleeffect chiller [13].
ABSORPTION
COOLING
TECHNOLOGY
As it has already been said, absorption cycles have some common
characteristics with vapour compression cycles, but they differ in two important
aspects:
30
Figure 15. Comparison between compression and absorption technologies using ammonia as
refrigerant and cooling water with a temperature of 25 C [10]
31
As it can be observed from the diagrams (Figure 15.), COP for absorption
technology is much less affected by a drop in evaporating temperature. This is a
significant advantage in overall economy. [11]
Initial costs for an absorption system are higher than for a compressor one
of the same cooling capacity as:
Absorption system needs more metallic materials in heat exchangers.
Lower pressures are requiered in absorption technologies, which implies
higher diameter of tubes in order to reduce pressure losses.
Size of condenser water pump is generally a function of flow rate per unit
cooling capacity. Cooling technologies with lower COP typically require a
significantly higher condenser water flow rate and, consequently, a larger
pump too, than those technologies with higher COP. Similarly, absorption
chillers require larger cooling tower capacity than electric chillers because of
larger volume of water.
It is needed more space for absorption systems since the equipments are
bigger.
In addition, cost and volume of absorption machines increase when temperature of
the generator is low.
32
from 8 to 9 times higher than the cost of heat. In CHP plants, high investment cost
of absorption machines are thwart by the more efficient use of fuel (see Table 4.).
Table 4. Energy saving with cogeneration for 4 = 0,54
SEPARATE
SEPARATE
TOTAL FUEL
ELECTRICITY
HEAT
CHP
production
production
CONSUMPTION
(condensing plants) (steam boiler)
FUEL
CONSUMPTION
EFFICIENCY
ELECTRICITY
PRODUCTIOIN
HEAT
PRODUCTION
100
73,3
63,6
0,88
0,42
0,9
30,8
30,8
57,2
57,2
136,9
Electric-thermal ratio: = Wel/Qheat = el/t where Wel is the electrical power output, Qheat is the
useful thermal power output, el is the electrical efficiency and t is the thermal efficiency.
33
The earliest three characteristics are the most important criteria when comparing
absorption systems with vapour compression systems.
SCALE
[kWcooling]
0,7
20-50
120
>250
1,2
15-40
150-170
>350
0,5
10-25
>100
1-5
34
CHAPTER 3
Figure 17. District cooling system (or district heating system6) [15]
36
District energy systems enable to use energy in a more efficient way and
reduce greenhouse gas emissions because, on the one hand, it is used a central
refrigeration plant instead of many small machines which are less efficient and, on
the other hand, it is produced electricity for the central grid that can replace other
electricity sources such as coal-fired plants.
3.1. PRODUCTION
3.1.1. COGENERATION. BENEFITS WITH INTEGRATION
OF COOLING TECHNOLOGY
Cogeneration (combined heat and power, CHP) is the use of a power
station for simultaneous generation of both electricity and useful heat
(conventional power plants produce but not use a large amount of heat). That is, it
is an energy conversion technology where two separate systems are integrated
together by a cascade of thermal energy [14]. Thus, it can be led to increase the
system performance7 by designing systems that can use the heat: the efficiency of
energy production can be increased from current levels that range from 35% to
55%, to over 80% [16]. In addition, some of the obligatory heat rejection is at a
high enough temperature to supply energy for comfort heating and cooling.
Figure 18. An schematic of cogeneration process that shows the consumed and produced
power in the whole system [15]
37
This way, shopping malls and blocks of business, university and collages,
hospitals, industries and so forth take the advantage of the economic benefits
provided by a central plant, through the use of boilers that produce hot water or
steam for heating and vapour compression or steam-driven absorption
refrigeration machines that produce chilled water for cooling.
Table 7. Different types of plants using a steam boiler and their characteristics
Flexible, low operating and investment costs
HEATING CONDENSING
BOILER
CHP plant
TRIGENERATION plant
(BIOFUELED STEAM BOILER)
38
Control valves must regulate the flow, but the pressure too. The available
differential pressure becomes lower at substations which are furthest away in the
system (because of greater pressure drops caused by the increased flow in the
distribution system) and it might not be enough for the required flow. Hence,
either another pump has to be used or the speed of the existing one has to be
increased to maintain the differential pressure. [15]
39
There are polyethylene (PE), polypropylene (PP), PVC and PEX pipes, in
addition to steel and cooper ones. For water applications, PE pipes are widely
used because their quality is high and they are economic at the same time. This
way, polyethylene pressure pipes offer the following benefits:
-
Corrosion resistance
Joint thightness
Plastic pipes are much cheaper than, for instance, steel ones. As the last
ones are widely used in district heating systems, lets say that the material for
cooling pipes is less costly. Likewise, construction of networks works out cheaper
than as appropiate for district heating pipes.
40
CHAPTER 4
Process
4.1.
In addition, there is Kappa paper mill close to that boiler, which has
another oil boiler of 2 MW and produces steam at 12 bar for 80 hours per week9.
In this way, Bionr10 is thinking about building a new biofueled steam
boiler which would replace those two11. It is wanted to make the most of that and
it is therefore planning to produce electricity too. Ramboll consultancy has
considered building a biomass fired CHP plant based on Organic Rankine Cycle
(ORC), as a low capacity boiler to produce needed steam at roughly 70 bar (which
requires a sophisticate water purification system) and a turbine are much more
expensive.
8
9
10
11
It is a factory which is located in Gvle and produces confectionery, candy and pastilles.
It is working 5 days/week, not at weekends, and 16h/day, not during night.
It is a subsidiary of Gvle Energy AB, which owns the 45%. One of the customers of Bionr is
LEAF.
Although the operating times of the boilers are different, the new boiler can work at 2 MW
during the day and increase its capacity during the night, when it can be produced the steam
which is needed in the paper mill during the day (storage in accumulator vessels).
42
4. PROCESS
ORC units have high overall energy efficiency: 20% of the thermal power
is transformed into electric power, while 78% remains as steam. Nowadays, it is
planning to build a TURBODEN 14 CHP plant that costs 5 300 000 SEK and
which performance is 1,26 MW of net active electric power and 5,35 MW of
steam ( = 0,23), with a biomass consumption of 7,63 MW.
.
Figure 21. Energy efficiency of ORC units in cogeneration applications
(Source: http://www.turboden.it/en/products.asp)
Gvle Energi AB, as knows of this project, might take the opportunity to
use this installation turning it into a trigeneration plant by means of introducing an
absorption cooling system that would use the steam produced in it. Hence, it is
needed an even bigger ORC unit and to make a decision about it is one of the
tasks of this project.
43
4. PROCESS
Figure 22. Johannes CHP plant before 2003 (Source: Gvle Energi AB)13
The steam boiler was built in 1999, which aim is to produce heat to deliver
in the district heating network of the municipality. It is a Bubble Fluidized Bed
(BFB) boiler and has a maximum capacity of 77 MW, whereas the minimum
power output is 20 MW.
It owns all production facilities in Gvle Energi AB but it is owned 100% by Gvle Energi AB.
The turbine is missing since it was introduced in 2003.
44
4. PROCESS
Figure 23. Production of heat (for District Heating) and electricity at Johannes
45
4. PROCESS
4.1.3. MACKMYRA
Nowadays, Mackmyra Svensk Whisky is located in Valbo, at the outskirts
of Gvle. There is an electric boiler with a capacity of 850 kW that operates
continuously all over the year14, which is owned by Bionr.
Figure 24. Existing electric boiler in Mackmyra (Source: Gvle Energi AB)
It could be even thought about a bigger boiler and a third step could take
place. As well as for LEAF, Gvle Energi AB might turn it into a trigeneration
plant where cold would be produced by firing absorption cooling machines with
steam. It is estimated that it would be needed a ten times bigger boiler;
14
46
4. PROCESS
47
4. PROCESS
48
4. PROCESS
Figure 26. Three cooling production and customer sites and main pipes
49
4. PROCESS
Next Table 8. shows different cooling demands for the planned three
production sites (see Appendix 2.).
PRODUCTION
SITE/AREA
CUSTOMER
LEAF
LEAF/CITY CENTER
MACKMYRA/
KUNGSBCK
COOLING
DEMAND
[MW]
2,5
CITY CENTER
9,0
11,5 TOTAL
MACKMYRA
HOSPITAL
UNIVERSITY
TECHNOLOGIC PARK
0
1,7
1,8
1,0
5,0 TOTAL
JOHANNES
HEMLINGBY SHOPPING
JOHANNES/
CENTERS
JOHANNESBERGSVGEN
1,4
2,0
3,4 TOTAL
50
4. PROCESS
Table 9. Possibilities to fulfill the cooling demand in the city center by using steam-fired
absorption chillers
DOUBLE-EFFECT STEAMSINGLE-EFFECT STEAMPRODUCTION
SITE
LEAF
FIRED ABSORPTION
FIRED ABSORPTION
CHILLER: TSA-16NK- 81
CHILLER: TSA-16TJ- 53
NUMBER OF CHILLERS
NUMBER OF CHILLERS
51
4. PROCESS
Table 10. Possibilities to fulfill the cooling demand in Kungsbck by using steam-fired
absorption chillers
DOUBLE-EFFECT STEAMSINGLE-EFFECT STEAMPRODUCTION
SITE
FIRED ABSORPTION
FIRED ABSORPTION
CHILLER: TSA-16NK- 81
CHILLER: TSA-16TJ-53
NUMBER OF CHILLERS
NUMBER OF CHILLERS
MACKMYRA
Table 11. Possibilities to fulfill the cooling demand corresponding to Johannes plant
SINGLE-EFFECT HOT WATER-FIRED
PRODUCTION
SITE
JOHANNES
52
4. PROCESS
Table 12. Cooling that should be produced for different sites during the year
COOLING
POWER PRODUCTION [kW]
TIME PERIOD
Winter time: 15 November-15 March
15 March-1 April & 1-15 November
April & 15 October-1 November
1-15 May & 15 September-15 October
15 May-15 June & 15 August-15 September
Summer time: 15 June-15 August
LEAF
895
3512
4683
6749
9779
MACKMYRA
389
1527
2036
2934
4252
JOHANNES
1556
2011
2214
2574
3101
11500
5000
3400
Figure 27. Cooling power to be produced in different sites during the year
In winter the cooling demand is very low. Hence, there is no need for
producing cooling at LEAF (899 kW) and Mackmyra (389 kW) due to the fact
that free cooling is allowed in this time of the year15. With regards to Johannes
(1556 kW), there is no river around the plant, so it is necessary to fulfil the
demand in another way. As heat demand is the highest in winter, produced hot
water cannot be used for firing absorption chillers (all heat ought to be delivered
in the district heating network) and consequently, the best solution would be to
use the already existing cooling and HVAC systems in Hemlingby and Johannes
during winter.
15
The river is far away from Mackmyra production site but the customers (university and
hospital) are quite close to it. Therefore, it is possible to introduce heat exchangers there for
free cooling in this area.
53
4. PROCESS
Cooling towers.
Chilled water pumps and cooling water pumps for each chiller.
Strainier, pressure gauge and drain trap, which should be near the steam inlet,
for each chiller.
Air vent valve in each of the chilled and cooling water lines.
Shut-off valve to prevent the steam flow into the chiller during shut-down.
Etc.
Regarding cooling towers, they produce cold water for cooling down
absorbers and condensers inside the chillers and their size is decided according to
the required cooling power. This equipment can be replaced by a heat exchanger
at LEAF, as water from the river is cold enough.
54
4. PROCESS
Lastly, there are two more heat exchangers which are planning to be used
for free cooling at LEAF and Mackmyra in winter time.
55
CHAPTER 5
Results
862,78
856,93
2,62
1,72
750,96
1412,95
1704,61
3,90
2,56
1483,92
2811,27
2902,07
9,22
4,54
2543,56
4785,81
6571,49
21,61
9,46
5759,41
10836,57
15 June-15 August
8487
23,73
12,99
7438,75
13993,87
862,78
20 522,10
61,08
31,27
TOTAL [MWh/year]
16
17 976,60 33 840,46
Operation hours data are taken from Anders Kedbrant estimations, Table A1. 15. (Appendix 1.), for all calculations because of lack of information.
57
5. RESULTS
Table 14. Biofuel (for producing steam), electricity and water consumption. LEAF
16NK-81
16TJ-53
25,71
48,39
TOTAL BIOFUEL CONSUMPTION17 [GWh/year]
61,08
31,27
CHILLERS
ELECTRIC POWER
450,82
REST OF THE PLANT18
SUPPLY [MWh/year]
511,91
482,10
TOTAL
5.1.1.2. COSTS
5.1.1.2.1. INVESTMENT COSTS
Table 15. Investment costs [SEK] for LEAF
3 ABSORPTION CHILLERS
5 ABSORPTION CHILLERS TSA-16TJ- 53
3 * 6 200 000
TSA-16NK- 81 (CARRIER-SANYO)
(CARRIER-SANYO)
BACK-UP COMPRESSOR CHILLER 19
BACK-UP COMPRESSOR CHILLER
600 000
YRTBTBT0550C (YORK)
YRTBTBT0550C (YORK)
3 HEAT EXCHANGERS
S121-IS10-502-TMTL47-LIQUIDE (Sondex)
5 HEAT EXCHANGERS (+ FILTER)
3 * 619 000
+
MX25-MFMS (Alfa Laval)
FILTERS BSG350/1,0P (Bernoulli)
HEAT EXCHANGER (+FILTER)
HEAT EXCHANGER (+FILTER)
120 000
TL10-BFG
TL10-BFG
REST OF THE INSTALLATION20
1 450 000
REST OF THE INSTALLATION
22 627 000
TOTAL [SEK]
TOTAL [SEK]
NOTE: all specifications are in Appendix 3.
17
18
19
20
5 * 2 700 000
600 000
5 * 550 000
120 000
1 450 000
18 420 000
Biofuel consumption in the ORC CHP plant (TURBODEN 14) = 1,43 MW biofuel/MW steam
Reference: Falun Cooling Project (see Appendix 6.).
Considered operation hours = chillers operation hours. It is known that submersible pumps for the whole installation are working the whole year
but data about them is missing.
It has been assumed the same for both Mackmyra and Johannes production plants.
The considered back-up chiller is the one planned for compression refrigeration project (VKA3). It is only considered its investment cost as it is not
usually running (it is just started up because of breakdowns and when the cooling demand is higher than the expected one). Calculations for
Mackmyra and Johannes production sites are also based on the same compressor.
Reference: Falun Cooling Project (see Appendix 6.).
It has been assumed the same for both Mackmyra and Johannes production plants.
58
5. RESULTS
16TJ-53
7 984 657,3
482 095,36
8 466 752,7
OPERATING
PROFITS: ELECTRICITY
PRODUCTION [SEK]
- 770 SEK/MWh-23
TOTAL [SEK]
47 534 854
70 164 854
18 420 000
84 667 527
- 31 836 561
- 59 931 460
38 328 293
43 156 067
Maintenance costs are very low because there are few components that
demand maintenace and there is just cleaning work mainly. As a result, these
costs can be neglected.
21
22
23
59
5. RESULTS
Next graph, Figure 29., compares all costs for different chillers sets at
LEAF.
Figure 29. Graph that shows the breakdown of total costs for 10 years at LEAF
After ten years, there are only operational costs, which are lower for
16NK-81 chillers set. If profits due to electricity production are taken into
account, costs for fulfilling customers demand in the city center will be
1 569 829 SEK/year and 2 473 607 SEK/year for 16NK-81 and 16TJ-53 chillers
set installations respectively.
60
5. RESULTS
5.1.2. MACKMYRA
5.1.2.1. OPERATIONAL CONDITIONS
Table 18. Power and steam demand of different chillers sets for the required cooling load in Mackmyra production during the year
NUMBER OF
POWER SUPPLY
STEAM SUPPLY
CHILLERS
COOLING LOAD [MWh]
TO CHILLERS
TO CHILLERS
WORKING
[MWh]
[MWh]
TIME PERIOD
FREE
ABSORPTION
16NK-81 16TJ-53
16NK-81 16TJ-53 16NK-81 16TJ-53
COOLING
COOLING
15 November-15 March
375
372,59
2,62
0,86
326,51
614,35
741,10
3,90
1,28
649,46
1221,98
1261,62
4,61
3,03
1105,60
2080,23
2857,34
7,20
4,73
2503,99
4711,36
15 June-15 August
3690
15,82
5,20
3233,68
5989,37
375
8922,66
34,15
15,09
7819,23
14 617,29
TOTAL [MWh/year]
Table 19. Biofuel (for producing steam), electricity and water consumption. Mackmyra
16NK-81
16TJ-53
24
11,18
20,90
TOTAL BIOFUEL CONSUMPTION [GWh/year]
34,15
15,09
CHILLERS
26,32
43,49
COOLING TOWERS (fans)
ELECTRIC POWER
SUPPLY [MWh/year]
450,82
REST OF THE PLANT
511,30
509,40
TOTAL
37 147,6
34 148,2
TOTAL WATER FOR COOLING TOWERS [m3/year]
24
It has been assumed that the biofuel consumption in the future boiler at Mackmyra is the same as in the one at LEAF, as the boiler might be small
and its efficiency is not therefore very high.
61
5. RESULTS
5.1.2.2. COSTS
5.1.2.2.1. INVESTMENT COSTS
Table 20. Investment costs [SEK] for Mackmyra
2 ABSORPTION CHILLERS
2 ABSORPTION CHILLERS TSA-16TJ- 53
2 * 6 200 000
TSA-16NK- 81 (CARRIER-SANYO)
(CARRIER-SANYO)
BACK-UP COMPRESSOR CHILLER
BACK-UP COMPRESSOR CHILLER
600 000
YRTBTBT0550C (YORK)
YRTBTBT0550C (YORK)
2 * 2 700 000
600 000
2 COOLING TOWERS
OCT09HB05-5-90 (Vestas Aircoil)
2 * 1 595 000
2 COOLING TOWERS
OCT09HB03-3-120 (Vestas Aircoil)
2 * 998 000
60 000
60 000
1 450 000
17 700 000
1 450 000
9 506 000
62
5. RESULTS
INVESTMENT
OPERATING
PROFITS: ELECTRICITY
PRODUCTION [SEK]
- 770 SEK/MWh-25
TOTAL [SEK]
17 700 000
25 048 352
42 748 352
9 506 000
40 949 460
50 455 460
- 9 031 216
- 16 882 966
33 717 136
33 572 494
Next graph, Figure 30., compares all costs for different chillers sets in
Mackmyra production site.
Figure 30. Graph that shows the breakdown of total costs for 10 years
in Mackmyra production site
After ten years, if profits due to electricity production are taken into
account, costs for fulfilling customers demand in Kungsbck area will be
25
Assumption: = 0,15. It has to be quite smaller than for Johannes ( = 0,29) since the boiler is
smaller and works at lower pressure. The smaller the boiler is, the lower the efficiency is.
Moreover, the lower pressure in the boiler is, the lower electricity production is ( value
depends mainly on the pressure of the boiler).
63
5. RESULTS
1 601 714 SEK/year and 2 406 649 SEK/year for 16NK-81 and 16TJ-53 chillers
set installations respectively.
5.1.3. JOHANNES
5.1.3.1. OPERATIONAL CONDITIONS
Table 23. Power and hot water demand of chillers set for the required cooling load at
Johannes during the year
HOT
POWER
NUMBER OF ABSORPTION
WATER
SUPPLY TO
TIME PERIOD
16LJ-53
COOLING
SUPPLY TO
CHILLERS
CHILLERS
LOAD [MWh]
CHILLERS
[MWh]
WORKING
[MWh]
15 November-15 March
15 March-1 April
2
490,68
1,72
733,84
1-15 November
April
2
805,90
2,56
1204,65
15 October-1 November
1-15 May
2
1106,82
3,03
1654,47
15 September-15 October
15 May-15 June
2
2083,87
4,73
3115,98
15 August-15 September
15 June-15 August
2
2509,2
5,20
3750,75
6996,47
17,23
10459,69
TOTAL [MWh/year]
5.1.3.2. COSTS
Table 24. Biofuel (for producing steam), electricity and water consumption. Johannes
TOTAL BIOFUEL CONSUMPTION26 [GWh/year]
CHILLERS
HVAC systems (winter time)27
ELECTRIC POWER
COOLING TOWERS (fans)
SUPPLY [MWh/year]
REST OF THE PLANT
TOTAL
TOTAL WATER FOR COOLING TOWERS [m3/year]
26
27
16LJ-53
13,28
17,23
749,99
36,50
450,82
1254,55
28 753,8
64
5. RESULTS
1 450 000
8 800 000
INVESTMENT
OPERATING
PROFITS: ELECTRICITY
PRODUCTION [SEK]
- 770 SEK/MWhTOTAL [SEK]
8 800 000
35 613 955
44 413 955
- 23 356 493
21 057 462
Next graph, Figure 31., shows all costs for 10 years in Johannes
production site.
65
5. RESULTS
Figure 31. Graph that shows the breakdown of total costs for 10 years
in Johannes production site
After ten years, if profits due to electricity production are taken into
account, costs for fulfilling customers demand in Johannesbergsvgen area will
be 1 225 746 SEK/year.
66
5. RESULTS
5.1.4.1. LEAF
When cooling demand is 10% higher, one more 16 TJ-53 single-effect
absorption chiller is needed at LEAF. Hence, one more MX25-MFMS (Alfa Laval)
heat exchanger for cooling down single-effect chillers set (with six chillers in
parallel) has to be introduced too. Furthermore, it cannot be left behind that
cooling load is also higher in winter time (1012,7 kW).
Next Table 28. and Table 29. gather together new operational conditions
and total costs respectively.
Table 28. Operational conditions of different chillers sets at LEAF during the year when the
cooling demand is 10% higher than the estimated one
TOTAL
TOTAL
TOTAL STEAM
TOTAL BIOFUEL
ELECTRICITY
COOLING LOAD
SUPPLY
CONSUMPTION
SUPPLY
[MWh/year]
[MWh/year]
[MWh/year]
[MWh/year]
FREE ABSORP.
16NK-81 16TJ-53 16NK-81 16TJ-53 16NK-81
16TJ-53
COOL.
COOL.
976,24 23 198,59 20 331,87 41 420,45
515,81
489,85 29 074,58
59 231,24
Table 29. Total costs of LEAF absorption cooling plants for 10 years when the cooling
demand is 10% higher than the estimated one
16NK-81
16TJ-53
TOTAL
COSTS [SEK]
INVESTMENT
OPERATING
PROFITS: ELECTRICITY
PRODUCTION [SEK]
TOTAL [SEK]
28
22 627 000
53 131 141
75 758 141
21 670 000
102 630 077
- 36 007 749
- 73 355 610
39 750 391
50 944 467
Calculations in this Section 5.1.4. are based on the same assumptions and estimations as for the
three cases studied before.
67
5. RESULTS
Following Table 30. and Table 31. show, on the one hand, new total
cooling load and operational conditions; on the other hand, the total costs (take
note that investment costs are the same).
Table 30. Operational conditions of different chillers sets at LEAF during the year when the
cooling demand is 10% lower than the estimated one
TOTAL
TOTAL
TOTAL STEAM
TOTAL BIOFUEL
ELECTRICITY
COOLING LOAD
SUPPLY
CONSUMPTION
SUPPLY
[MWh/year]
[MWh/year]
[MWh/year]
[MWh/year]
FREE ABSORP.
16NK-81 16TJ-53 16NK-81 16TJ-53 16NK-81
16TJ-53
COOL.
COOL.
750,96 17 845,07 15 640,52 29 426,53
504,70
482,10 22 365,94
42 079,94
Table 31. Total costs of LEAF absorption cooling plants for 10 years when the cooling
demand is 10% lower than the estimated one
16NK-81
16TJ-53
TOTAL
COSTS [SEK]
INVESTMENT
OPERATING
PROFITS: ELECTRICITY
PRODUCTION [SEK]
TOTAL [SEK]
22 627 000
41 950 824
64 577 824
18 420 000
74 252 852
92 672 852
- 27 699 356
- 52 114 385
36 878 468
40 558 467
68
5. RESULTS
5.1.4.2. MACKMYRA
When cooling demand is 10% higher, one more 16 TJ-53 single-effect absorption chiller is also required in Mackmyra production
site. This way, one more OCT09HB03-3-120 (Vestas Aircoil) cooling tower is needed too. Likewise, roughly 39 kW cooling/year more
ought to be produced by means of free cooling in winter.
New total cooling load and operational conditions as well as total costs are shown in Table 32. and Table 33.
Table 32. Operational conditions of different chillers sets in Mackmyra production site during the year
when the cooling demand is 10% higher than the estimated one
TOTAL
TOTAL STEAM
TOTAL BIOFUEL
TOTAL WATER
TOTAL COOLING
ELECTRICITY
SUPPLY
CONSUMPTION
CONSUMPTION
LOAD [MWh/year]
SUPPLY
[MWh/year]
[MWh/year]
[m3/year]
[MWh/year]
FREE
ABSORP.
16NK-81 16TJ-53 16NK-81 16TJ-53
16NK-81
16TJ-53
16NK-81
16TJ-53
COOL.
COOL.
413,03
9 814,79 8 600,87 16 181,66
512,05
510,02
12 299,24
23 139,78
44 472,4
40 396,1
Table 33. Total costs of Mackmyra absorption cooling plants for 10 years
when the cooling demand is 10% higher than the estimated one
16NK-81
16TJ-53
INVESTMENT 17 700 000
44 893 151
OPERATING 27 193 151
PROFITS: ELECTRICITY
- 9 934 004
PRODUCTION [SEK]
34 959 146
TOTAL [SEK]
TOTAL
COSTS [SEK]
13 204 000
44 896 671
58 100 671
- 18 689 819
39 410 852
69
5. RESULTS
When cooling demand is 10% lower, it is only necessary one 16NK-81 double-effect absorption chiller (one less) and, therefore,
only one OCT09HB05-5-90 (Vestas Aircoil) cooling tower too. Regarding demanded cooling in winter, 351 kW are just required.
Following Table 34. and Table 35. gather together new total cooling load as well as operational conditions and total costs,
respectively.
Table 34. Operational conditions of different chillers sets in Mackmyra production site during the year
when the cooling demand is 10% lower than the estimated one
TOTAL
TOTAL STEAM
TOTAL BIOFUEL
TOTAL WATER
TOTAL COOLING
ELECTRICITY
SUPPLY
CONSUMPTION
CONSUMPTION
LOAD [MWh/year]
SUPPLY
[MWh/year]
[MWh/year]
[m3/year]
[MWh/year]
FREE
ABSORP.
16NK-81 16TJ-53 16NK-81 16TJ-53
16NK-81
16TJ-53
16NK-81 16TJ-53
COOL.
COOL.
337,93
8 030,28 7 036,80 13 240,73
511,07
498,42
10 062,62
18 934,24
27 893,3 34 148,2
Table 35. Total costs of Mackmyra absorption cooling plants for 10 years
when the cooling demand is 10% lower than the estimated one
16NK-81
16TJ-53
TOTAL
COSTS [SEK]
INVESTMENT
OPERATING
PROFITS: ELECTRICITY
PRODUCTION [SEK]
TOTAL [SEK]
9 905 000
22 829 801
32 734 801
9 506 000
37 591 672
47 097 672
- 8 127 503
- 15 293 040
24 607 298
31 804 632
70
5. RESULTS
5.1.4.3. JOHANNES
The installations remain the same in Johannes production site when
cooling demand is 10 % higher or lower. Cooling load and hence, operational
conditions are only changed.
Next Table 36. and Table 38. show the new operational conditions and
Table 37. and Table 39. the consistent new total costs.
Table 36. Operational conditions of different chillers sets in Johannes production site during
the year when the cooling demand is 10% higher than the estimated one
TOTAL
TOTAL HOT
TOTAL
ABSORPTION
TOTAL BIOFUEL TOTAL WATER
WATER
ELECTRICITY
COOLING
CONSUMPTION CONSUMPTION
SUPPLY
SUPPLY
LOAD
[MWh/year]
[m3/year]
[MWh/year]
[MWh/year]
[MWh/year]
7 353,12
10 991,43
1 268,15
13 959,11
28 753,8
Table 37. Total costs of Johannes absorption cooling plants for 10 years
when the cooling demand is 10% higher than the estimated one
16LJ-53
TOTAL
COSTS [SEK]
INVESTMENT
OPERATING
PROFITS: ELECTRICITY
PRODUCTION [SEK]
TOTAL [SEK]
8 800 000
36 864 168
45 664 168
- 24 543 860
21 120 308
Table 38. Operational conditions of different chillers sets in Johannes production site during
the year when the cooling demand is 10% lower than the estimated one
TOTAL
TOTAL HOT
TOTAL
ABSORPTION
TOTAL BIOFUEL TOTAL WATER
WATER
ELECTRICITY
COOLING
CONSUMPTION CONSUMPTION
SUPPLY
SUPPLY
LOAD
[MWh/year]
[m3/year]
[MWh/year]
[MWh/year]
[MWh/year]
6 639,31
9 923,21
1 241,36
2 079 408,443
28 324,8
Table 39. Total costs of Johannes absorption cooling plants for 10 years
when the cooling demand is 10% lower than the estimated one
16LJ-53
TOTAL
COSTS [SEK]
INVESTMENT
OPERATING
PROFITS: ELECTRICITY
PRODUCTION [SEK]
TOTAL [SEK]
8 800 000
34 340 656
43 140 656
- 22 158 526
20 982 130
71
5. RESULTS
5.2.
COMPRESSION
TECHNOLOGY
VERSUS
ABSORPTION TECHNOLOGY. COMPARISON
FOR LEAF PRODUCTION SITE
Technological possibilities and aspects of absorption cooling systems at
three specific sites in the victinity of Gvle, as well as the costs and profits
(economic aspects), have been evaluated. Nevertheless, the main aim of this thesis
is to analyze possible benefits with the use of heat driven absorption chillers
instead of conventional vapour compressor chillers. Thus, compression cooling
machines at LEAF have been replaced by equivalent absorption ones in order to
make a comparison.
This way, four double-effect steam fired absorption chillers are going to be
introduced: two 16NK-41 (1371 kW) and other two 16NK-71 (3446 kW), which
has been choosen taking into account different sizes and models of chillers that
exist in the market. Both VKA1 and VKA2 could be replaced with just a single
bigger absorption machine (16NK-62); nevertheless, five machines ought to be in
total so that absorption cooling installation would have been also built in two
stages31. Likewise, an installation with single-effect absorption chillers is not
29
30
31
KM1 pumps are not taken into consideration as electricity consumption of absorption chillers,
which belongs with pumps, is calculated. Regarding distribution pumps, those are taken into
account in this case as they are also included in the costs of the refrigeration compression
installation.
Compression cooling plant is using free cooling not only in winter but all around the year
except for May-August (altogether 1936 h/year). Even though it is not right (it should be used
only in winter time: 15 November-15 March), the same operational conditions have been
considered so that new calculations are comparable with the existing compression project.
There are only VKA1 and VKA2 cooling machines in the first stage of the compressor
refrigerant cooling project and one of them is a back-up chiller. For that reason, there are two
small compressor chillers when the installation is totally built (in addition to VKA4 and
VKA5) instead of a bigger one.
72
5. RESULTS
studied since more than four absorption chillers would be needed (their maximum
capacity is 2461 kW).
Table 41. Power and steam demand of chillers set for the required cooling load in the
existing cooling project but with absorption machines
VKA1 16NK-41,1 VKA4 16NK-71,1
TOTAL
VKA2 16NK-41,2 VKA5 16NK-71,2 [MWh/year]
STEAM SUPPLY
2 * 876,51
2 * 2249,84
6252,67
TO THE CHILLERS
[MWh/year]
TOTAL POWER SUPPLY
2 * 9,78
2 * 15,99
51,53
TO THE CHILLERS
[MWh/year]
TOTAL BIOFUEL
2 * 1253,42
2 * 3217,30
8941,37
CONSUMPTION
[MWh/year]
Table 42. Operational costs in the existing cooling project but with absorption machines
51 530,11
CHILLERS
ELECTRICITY [SEK/year]
- 1 SEK/kWh3 192 656
REST OF THE EQUIPMENTS
1 475 326,19
BIOFUEL [SEK/year] - 165 SEK/MWh4 719 512,30
TOTAL [SEK/year]
Table 43. Total costs of the existing cooling project but with
absorption machines for 10 years
VK3
600 000
COOLING
16NK-41
2 * 3 000 000
EQUIPMENTS
16NK-71
2 * 5 300 000
BUILDING
4 000 000
INVESTMENT COSTS
[SEK]
PIPES INSIDE THE BUILDING
4 500 000
PUMPS AND FILTERS
3 000 000
INSIDE THE BUILDING
TOTAL
28 700 000
47
195
123
COSTS OF OPERATION [SEK]
PROFITS: ELECTRICITY
- 11 073 544
PRODUCTION [SEK]
- 770 SEK/MWhTOTAL [SEK]
64 821 579
73
5. RESULTS
Next Figure 32. gathers together all information about both cooling installations at LEAF.
8941 MWh
biofuel
165 SEK/MWh
ORC
= 0,23
6253 MWh
steam
3245 MWh
electricity
0,001 SEK/MWh
7143 MWh
COOLING
MAINTENANCE
COSTS
[SEK]
= 170 000 x
when x = 1 x: years
when 1 < x 5
when x 6
4241 MWh
electricity
0,001 SEK/MWh COMPRESSION COOLING INSTALLATION
22 629 000 SEK
7143 MWh
COOLING
Figure 32. Comparison of cooling installations with absorption and compression machines at LEAF
74
5. RESULTS
PRODUCTION
SITE
PIPE
KWH PE
(PN10)
LEAF
LEAF
1370
175
200
Mackmyra I
500
262
315
Mackmyra II
310
166
200
Mackmyra III
1890
203
250
Johannes
1775
370
450
MACKMYRA
JOHANNES
P
[kPa]
(in the
distribution
system)
771
328
317
250
171
718
75
CHAPTER 6
Discussions
Amount of provided information was limited and to collect accurate
information was difficult. Therefore, results are only approximations, as they are
based on quiet a lot assumptions. As a result, definitive conclusions cannot be
come up with.
at
LEAF.
Nevertheless,
3 713 268 SEK lower per year, which means that the initial extra costs would be
paid back in less than 2 years. If profits due to electricity output are taken into
consideration, the difference in annual costs would not be so large, but still
903 778 SEK/year (in this case, higher investment costs would be paid back in
5 years).
On the other hand, despite double-effect facilities cost 8 194 000 SEK
more
than
single-effect
ones
at
Mackmyra,
operational
costs
are
77
6. DISCUSSIONS
1 590 110 SEK lower per year. As a result, the extra investment costs are paid
back in 5 years. This time rises up to 10 years if produced electricity is taken into
account.
Therefore, needless to say that it is more profitable to introduce doubleeffect chillers in both sites, since the pay-back times for extra investments are
short and the earnings would be considerable. This way, costs and profits for the
possible future three absorption cooling plants in Gvle would be those that are
gathered together in the following Table 47.
Table 47. Most adequate chillers and costs & profits for the three production sites
PROFITS
OPERATIONAL
FROM
PRODUCTION ABSORPTION
INVESTMENT
COSTS
ELECTRICITY
SITE
CHILLERS SETS
COST [SEK]
[SEK/year]
PRODUCTION
[SEK/year]
3 double-effect
LEAF
chillers (4652 kW)
22 627 000
4 753 785
3 183 656
in parallel
2 double-effect
MACKMYRA chillers (4652 kW)
17 700 000
2 504 835
903 122
in parallel
2 single-effect hot
water chillers
JOHANNES
8 800 000
3 561 396
2 335 649
(1846 kW) in
parallel
Next graph in Figure 33. shows total heat that might be produced in
different biofuel boilers for the three absorption plants and accordingly obtained
extra electricity output.
78
6. DISCUSSIONS
Figure 33. Increased heat load for the three absorption plants and the possible extra
electricity that would be produced
In Figure 23. was shown that when the load in the district heating network
is low there is almost none electricity production in Johannes CHP plant. In
addition, it is shut down during summer, June-August. If heat driven absorption
chillers were introduced, heat load and therefore, electricity output, would be
increased as it is shown in the next graph in Figure 34.
Figure 34. Increased heat and electricity load in the probable Johannes trigeneration plant
79
6. DISCUSSIONS
Nevertheless, this heat load would not be even enough to keep the boiler
running during summer because of efficiency problems, that is, the minimum
working capacity. The graph in Figure 35. shows that the boiler would have to
work at around 5 MW, whereas it is shut down when the loading is lower than
25% of its maximum capacity (20 MW).
Figure 35. Required operational conditions of the boiler for the cooling plant at Johannes
6.2.
6. DISCUSSIONS
Figure 36. Comparison of total costs for ten years for the different cooling production
technologies at LEAF
Next Table 48. gathers together annual benefits after the first 10 years
when using absorption chillers instead of compression cooling machines:
Table 48. Annual benefits of absorption cooling technology at LEAF after 10 years
PROFITS
ELECTRICITY ELECTRICITY
FROM
CASE
CONSUMPTION PRODUCTION
ELECTRICITY
[MWh/year]
[MWh/year]
[SEK/year]
LEAF 8905 kW
- 996
1438
1 107 354
32
It bears reminding from Section 2.3. that absorption systems can compete against compression
ones when price of electricity is around 8 times higher than cost of heat.
81
6. DISCUSSIONS
This way, it is come to the conclusion that a sustainable energy system for
Gvle for meeting the cooling demand can be the erection of district cooling
networks with trigeneration plants by producing cooling in heat driven absorption
cooling machines. Increasing of the energy system with a third output (cooling)
would optimize the system even more. Furthermore, it is also very good from
environmental point of view, since extra electricity produced could be sold as
green in the Swedish market and it could replace, this way, margin produced
electricity.
It bears mentioning that the system border of electricity production and
consumption has to be taken into consideration when studying environmental
aspects and, like this, carbon dioxide emissions. From global point of view,
electricity production in Gvle would affect European energy system and total
33
34
82
6. DISCUSSIONS
CO2 emissions would be therefore negative. However, the local emissions would
be negatively affected because of increased use of fuel; anyway, biofuel, that is,
clean fuel, would be used.
83
6. DISCUSSIONS
JOHANNES
84
6. DISCUSSIONS
constant with variations of 10% in cooling demand. This means the same
machines can be used to produce up to 10% more than required cooling nowadays
with higher profits, as electricity output together with income from customers
increase while variation in costs of operation is little.
On the other hand, steam-fired chillers are under study. The trend at LEAF
is the same as at Johannes. However, there is a big difference at Mackmyra when
demand decreases by 10%: investment costs are 44% lower. Therefore, the best
option would be to build smaller installations and meet the cooling demand in
Kungsbck area by other means. This could be accomplished in two different
ways: by storing energy or by making the network smaller and using another.
85
CHAPTER 7
Conclusions
This research seeks to compare compression and absorption cooling
technologies and to make a decision about which one is the best solution, in
addition to deal with the analysis of three trigeneration plants with absorption
cooling systems in Gvle. In connection with this, next all interesting made
conclusions are summed up and gathered together.
87
REFERENCES
REFERENCES
[1] T.T. Chow, K.F. Fong, A.L.S. Chan, R.Yau, W.H. Au, V. Cheng, Energy
modelling of district cooling system for new urban development, Energy and
Building 36 (2004) 1153-1162.
[2] L. Trygg, B. G. Karlsson, Industrial DSM in a deregulated European
electricity market-a case study of 11 plants in Sweden, Department of
Mechanical Engineering, Division of Energy Systems, Linkping Institude of
Technology, Linkping S-581 83, Sweden.
[3] A. Rojey, Cold producing process, 4,037,426 United States Patent.
[4] M. J. Moran, H. N. Shapiro, Fundamentos de termodinmica tcnica
(Fundamentals of Engineering Thermodynamics), Revert (2004). ISBN 84291-4313-0.
[5] United States Departament of Energy (DOE), Mississippi Cooling, Heating,
and Power (micro-CHP) and Bio-fuel Center, micro- Cooling, Heating, and
Power (m-CHP) Instructional Module, Mississippi State, MS 39762
(December 2005 First Printing).
[6] R. Gianfrancesco, Method and apparatus for the absorption-cooling of a fluid,
5,177,979 United States Patent.
[7] R. Daro Ochoa V., Absorcin como una alternativa de ahorro de energa
(Absorption as alternative for saving energy), Tecnologa Empresarial S.A.
(2003).
[8] A. encan, K. A. Yakut, S. A. Kalogirou, Exergy analysis of lithium
bromide/water absorption systems, Renewable Energy 30 (2005) 645-657.
[9] G. Cohen, A. Rojey, Absorbers used in absorption heat pumps and
refrigerators, 4,299,093 United States Patent.
[10] Y. Hassan, Cold from Waste Energy. The Absorrption System, Mechanical
Department, Sudan University.
[11] D W Hudson, Gordon Brothers Industries Pty Ltd, Ammonia absoption
refrigeration plant, The official journal of AIRAH (August 2002).
[12] I. Horuz, A comparison between ammonia-water and water-lithium bromide
solutions in vapor absorption refrigeration systems, PII S07351933(98)00058-X.
[13]M. Rydstrand, Heat driven cooling in district energy systems, KTH Chemical
Engineering and Technology, Stockholm (2004). ISBN 91-7283-794-2.
[14] K.E. Herold, R.Radermacher, S. A. Klein, Absorptioni Chillers and Heat
Pumps, CRC Press (1996). ISBN 0-8493-9429-9.
89
REFERENCES
INTERNET SOURCES:
1. http://www.air-conditioning-and-refrigeration-guide.com/refrigerationcycle.html
2. http://www.qrg.northwestern.edu/thermo/design-library/refrig/refrig.html,
Design of Vapour-Compression Refrigeration Cycles
3. http://www.commercial.carrier.com, Absorption Chillers
4. http://www.nationmaster.com/encyclopedia/Gas-absorption-refrigerator
5. http://www.grappa.co.yu/b/index.php?page=shop.getfile&file_id=36&product_
id=48&option=com_virtuemart&Itemid=30, Carrier-Sanyo Super Absorption
16LJ 11-53
6. http://www.kwhpipe.com
7. http://www.carrier.com
8. http://www.turboden.it/en/products.asp
BROCHURES:
1.
2.
3.
4.
5.
6.
90
REFERENCES
PERSONAL CONTACTS:
NAME
ke Bjrnwall
Hkan Rannestig
Ulf Hedman
Anders Kedbrant
COMPANY/ CAPACITY
Gvle Energi AB: Project & Development
Supervisor
Gvle Energi AB: Manager P&U
INFORMATION
Tel direct 026 17 86 15
ake.bjornwall@gavle.se
026-17 26 60
AREA OF EXPERTISE
- General
- Gvle Energi
Cooling project
- Boiler-projects
- Absorption cooling
- Existing project
- Compression
Refrigeration
Customer data
GIS
Distribution system
Per-Arne Vahlund
Inger Wiklund
Greger Berglund
Lucas Enstrm
026-17 26 65
lucas.enstrom@gavle.se
Daniel Widman
Sale assistants: Tomas Lundgren and Tyko Sandell from Carrier, Thomas Nystrm from Z&I Pumps, Anna Schlegel
from Grudfos, Robert Lindberg from Baltimore Air Coil (BAC), etc.
91
APPENDICES
A1.1. INSTALLATION
Figure A1. 1. Draft of the whole compression installation (Source: Anders Kedbrant, SWECO)
93
2nd stage
1st stage
2nd stage
1st stage
Figure A1. 2. Draft of the devices of the compression installation (Source: Anders Kedbrant, SWECO)
94
5,5 C
RETURN PIPE:
13,2 C
PUMPS:
Table A1. 1. Pump specifications of compression cooling installation I
TYPE
PROCEDURE
MEDIA
FLOW
MAXIMUM PRESSURE
POWER
RATED CURRENT
MINIMUM EFFICIENCY
KM1-P6A / P6B
(SUBMERSIBLE, BRUNN1, BRUNN2)
DRY SINGLE PUMP
Wilo / FA 25.93D WITH ENGINE FK34.16/50
WATER 20C
265 l/s
150 kPa
75 kW
151 A
88 %
95
TYPE
PROCEDURE
MEDIA
FLOW
MAXIMUM PRESSURE
POWER
RATED CURRENT
MINIMUM EFFICIENCY
KB1-P6A / P6B
Grundfos / : TP300/590/4 A-F-A DBUE or
equivalent
WATER 5,5C
320 l/s
400 kPa
200 kW
340/196 A
---
TYPE
PROCEDURE
MEDIA
FLOW
MAXIMUM PRESSURE
POWER
RATED CURRENT
MINIMUM EFFICIENCY
KB1-P1, KB1-P2
DRY SINGLE PUMP
Wilo / : IL 150/190-5,5/4 or equivalent
WATER 5,5C
45 l/s
50 kPa
5,5 kW
11,4 A
71 %
TYPE
PROCEDURE
MEDIA
FLOW
MAXIMUM PRESSURE
POWER
RATED CURRENT
MINIMUM EFFICIENCY
KB1-P3
DRY SINGLE PUMP
Wilo / IL 80/170-2,2/4
WATER 5C
25 l/s
50 kPa
2,2 kW
4,7 A
67 %
TYPE
PROCEDURE
MEDIA
FLOW
MAXIMUM PRESSURE
POWER
RATED CURRENT
MINIMUM EFFICIENCY
KB1-P4, KB1-P5
DRY SINGLE PUMP
Wilo / IL 200/240-15/4
WATER 5C
110 l/s
70 kPa
15 kW
28,5 A
76 %
96
TYPE
PROCEDURE
MEDIA
FLOW
MAXIMUM PRESSURE
POWER
RATED CURRENT
MINIMUM EFFICIENCY
KM1-P1, KM1-P2
DRY SINGLE PUMP
Wilo / IL 100/170-3/4
WATER 20C
40 l/s
45 kPa
3 kW
6,4 A
73 %
TYPE
PROCEDURE
MEDIA
FLOW
MAXIMUM PRESSURE
POWER
RATED CURRENT
MINIMUM EFFICIENCY
KM1-P3
DRY SINGLE PUMP
Wilo / IL 100/160-2,2/4
WATER 5C
30 l/s
45 kPa
2,2 kW
4,7 A
77 %
TYPE
PROCEDURE
MEDIA
FLOW
MAXIMUM PRESSURE
POWER
RATED CURRENT
MINIMUM EFFICIENCY
KM1-P4, KM1-P5
DRY SINGLE PUMP
Wilo / IL 200/240-7,5/6
WATER 5C
80 l/s
50 kPa
7,5 kW
16 A
74 %
CHILLERS:
Table A1. 9. Vapour Compressor chillers specifications I
TYPE
REFRIGERANT
MAXIMUM CAPACITY
INPUT POWER
VOLTAGE
VKA1, VKA2
MODEL: YRWCWCT3550C
R134 A
1254 kW
187 kW
400/ 50 Hz
97
TYPE
REFRIGERANT
MAXIMUM CAPACITY
INPUT POWER
VOLTAGE
VKA3
MODEL: YRTBTBT0550C
R134 A
717 kW
110 kW
400/ 50 Hz
TYPE
REFRIGERANT
MAXIMUM CAPACITY
INPUT POWER
VOLTAGE
VKA4, VKA5
MODEL: YKKKKLH95CQF
R134 A
3226 kW
451 kW
400/ 50 Hz
TYPE/MANUFACTURER
CAPACITY
STREAMS TEMPERATURE
FLOW
PRESSURE DROP
KB1-VVX1 AlfaLaval
500 kW
4,5/15 C (primary)
5,5/165 C (secondary)
11,3 l/s (primary & secondary)
96,9 kPa (primary)
98,8 kPa (secondary)
VKA2 is a back-up chiller in the first stage. When the second stage is
built, both VKA1 and VKA2 will be working together with VKA4 and VKA5 and
VKA3 will be the back-up chiller (it is not considered for calculations).
All calculations, which are shown next, are for the whole installation.
98
940,5
7,524
33
487,08
458 098,74
50
627,0
7,377
41
605,16
379 435,32
25
315,5
4,679
23
339,48
1476
(see Table A1. 15.)
107 105,94
TOTAL
1 000 167,12
2419,5
7,830
33
487,08
1 178 490,06
50
1613,0
7,868
41
605,16
976 123,08
25
806,5
6,350
23
339,48
273 790,62
TOTAL
1476
2 571 251,04
NOTE: the following Table A1. 15. shows the operation hours.
Table A1. 15. Operating time for cooling delivering during the year
Month
Days
hours/day
hours/month
January
31
248
February
28
224
March
31
248
April
30
240
May
31
12
372
June
30
12
360
July
31
12
372
August
31
12
372
September
30
240
October
31
248
November
30
240
December
31
248
99
FIRST STAGE
Table A1. 16. Power needed in the compression cooling installation during the year
INPUT POWER
OPERATING TIME
INPUT
[kW]
[h/year]
LOAD
Winter
Winter
Shut down
[kWh/year]
time
time
compressors
KM1-P6A
75
22,5
1476
1936
6260
295 110
KM1-P6B
75
22,5
1476
1936
6260
295 110
KB1-P6A
KB1-P6B
200
200
60
60
1476
1476
1936
1936
6260
6260
786 960
786 960
VKA1/VKA2
see
Table
A1. 17.
1476
149 046,48
KB1-P1
KB1-P2
KM1-P1
KM1-P2
5,5
5,5
3
3
1476
1476
1476
1476
8118
8118
4428
4428
KB1-VVX1
500
1476
149 046,48
1476
359 465,04
1476
359 465,04
1476
1476
1476
1476
22 140
22 140
11 070
11 070
VKA2
SECOND STAGE
VKA3
VKA4
VKA5
KB1-P3
KB1-P4
KB1-P5
KM1-P3
KM1-P4
KM1-P5
see
Table
A1. 17.
110
see
Table
A1. 18.
see
Table
A1. 18.
2,2
15
15
2,2
7,5
7,5
TOTAL
1936
968 000
4 240 675,04
100
Working the whole year (when the compressors are shut down too)
30% of the total power is just used in winter time and when
the compressors are not working
It is ony used in winter time, when free cooling is allowed
NOTES:
-
Following Table A1. 17. and Table A1. 18. show input load for different
compressors in time steps.
Table A1. 17. Input load VKA1 and VKA2 compressors
(YRWCWCT3550C) in time steps
INPUT
OPERATING
INPUT
%
POWER
TIME
LOAD
LOAD
[kW]
[h/year]
[kWh/year]
100
187
44,28
8 280,36
75
140,25
487,08
68 312,97
50
93,5
605,16
56 582,46
25
46,75
339,48
15 870,69
1476
149 046,48
TOTAL
338,25
487,08
164 754,81
50
225,5
605,16
136 463,58
25
112,75
339,48
38 276,37
1476
359 465,04
TOTAL
Input loads for pumps should be calculated in the same way, as they
depend on the cooling load (system curve). Nevertheless, their design
curves are unkown and therefore, it has been considered they are working
at their maximum capacity except for winter time (and when compressors
are shut down too), when they work at 30% of the maximum capacity
(minimum capacity).
101
Finally, Table A1. 19. gathers together total needed load in the system and
operational costs.
Table A1. 19. Total input load and operating costs in the compression cooling installation
4 240 675
4 240 675
INVESTMENT
COSTS
[SEK]
COSTS OF
OPERATION
[SEK/year]
MAINTENANCE
COSTS
[SEK]
11 129 000
4 000 000
4 500 000
3 000 000
4 240 675
1st year
159 800
nd
th
2
3
5th
6th
10th
year
year
year
year
year
149 600 139 400 119 000 89 250 89 250 89 250
102
35
[SEK]
TOTAL [SEK]
42 406 750
1 168 750
66 204 500
Later on, after the first 10 years, there will be only operational and
maintenance costs.
35
Total maintenance costs are equal to the area under the curve in Figure A1. 3. This way, they
will be: (51000*5/2) + (119000-89250)*5 + (89250*10) = 1168750 SEK for ten years.
103
OWNER
Norrporten
Norrvidden
Dis Fastigheter
Table A2. 1. Cooling demand of possible future customers in the city center and additional data
NAME
COOLING
COOLING
OF
ADDRESS
N
INSTALLED
DEMAND
NOTES
ESTATE
[KW]
Yes
No
Kv Hvdingen,
N skepparg 2
1
X
150
Kv Notanus,
N Strandgatan 1
2
X
70
Kv Syndicus
Kyrkogatan 4
3
X
200
Lnsstyrelsen,
Borgmstarplan 2
4
X
Not interested
Polishuset
S Centralg 1-3
5
X
350
New cooling system installed 2007
Kv Vulkanus
S Sjtullsgatan
6
X
100
Byggforskningen
Kv Vasen
Lantmterigatan
7
X
700
Kv Kapellbacken
Skomakargatan 1
8
X
400
Skattehuset
Kv. Klockstapeln
Vgskrivargatan 5
9
X
200
Kv Gevalia
Nygatan 25-27
10
X
250
Cooling machine installed 2004
Kv Skamplen
11
X
400
Present cooling system contain R22.
Kv Lektorn
12
X
200
Cooling machine installed 1998
Norr 23:5
13
X
200
Old cooling machine which
(Skandihuset)
need to be replaced
Postterminalen
14
X
100
Kv Nattvktaren
15
X
700
Cooling machine installed 2000
Sankt George:1
16
X
40
Kv Hoppet
17
X
40
Kv Pechlin
Folksamhuset
18
X
100
New cooling machine installed 2005
104
OWNER
Gavlegrdarna
Gavlefastigheter
Kv Tomvkaren
Boetten
Kraft Foods
Handelsbanken
Lnsmuset
Jernhusen station AB
Banverket
Allokton
F2 Hyresbostder
Folkets Hus
Table A2.1 (continuation). Cooling demand of possible future customers in the city center and additional data
NAME
COOLING
COOLING
OF
ADDRESS
N
INSTALLED
DEMAND
NOTES
ESTATE
[KW]
Yes
No
Alderholmen
Building not erected yet.
19
X
30
servicehus
Kv Trhsten
Frvaltningshuset
20
X
400
Sure customer
Biblioteket
The library
21
X
700
Kommunhuset
22
X
300
Teatern
The theatre
24
X
300
Need cooling solution
Konserthuset
25
350
Problem with present solution
Boultbee
26
Have two machines built 2004
Kv Krrlandet
Nian
27
X
700
Cooling machines installed 2004.
Gamla domstolarna
28
X
45
Existing customer
Drottningatan 48
29
X
20
Kv Alderholmen
30
X
500
100 kW sure, 400 kW potential
Kv Skolstuvan
31
X
200
Kv Plantagen
The museum
32
X
250
Centralstationen
Railway station
33
X
60
New cooling machines installed 2005.
Kv Storn
34
X
100
Need to expand present capacity
Kv Gesllen
35
X
350
Kv Borgen
36
X
40
37
X
120
Not interested at present
Kv islandsskolan
38
X
40
Norr 23:3
39
X
100
Contact by SWECO
105
1700
UNIVERSITY
1800
TECHNOLOGIC PARK
1000
106
2000
107
SINGLE-EFFECT STEAM-FIRED
Carrier-Sanyo 16TJ
ABSORPTION
CHILLERS:
108
(Source: Carrier-Sanyo)
109
5460
kg
h
1h
3600 s
2675,5
kJ
kg
Thus,
16TJ-53
2,5 MW cooling
ABSORPTION
CHILLER
Take note that the relation between capacity of the chiller used and cooling
water power as well as steam needed can be considered linear (part-load curve is
almost linear). However, the cooling water flow is usually constant. That is, i.e. an
16TJ-53 absorption chiller working at 50% of its maximum capacity (1230,5 kW)
needs 2028,92 kW of satured steam and 3005,1 kW of cooling (the water flow is
159 l/s). With regards to the electric power supply (for pumps), it is constant.
110
111
(Source: Carrier-Sanyo)
112
5300
kg
h
1h
3600 s
2769,1
kJ
kg
Thus,
4,1 MW satured steam
at 8 bar
16NK-81
4,7 MW cooling
ABSORPTION
CHILLER
113
B. JOHANNES
Figure A3. 1. Water streams (steam and DH) at Johannes CHP plant (Source: Gvle Energi AB)
114
Next Table A3. 1. shows pressures of the first steam stream extracted from
the turbine related to electricity and district heating production capacities during
the year. The values in blue point out the steam cannot be used in absorption
chillers. The last four values belong to summer period, when the boiler is running
at its minimum capacity (20 MW).
Table A3. 1. Production data and pressure of the first steam stream extracted from the
turbine (Source: Gvle Energi AB)
ELECTRICITY
DISTRICT HEATING
P
[MW]
[MW]
[kPa]
23,704
56,168
1
24,367
59,375
1,044
20,531
55,589
2,25
19,848
52,422
2,23
21,738
50,532
0,8835
11,137
34,355
2,13
10,679
32,022
2,12
12,687
30,004
0,5511
3,602
18,624
2,05
3,683
18,555
2,05
4,244
15,991
0,7415
4,449
15,723
0,7409
4,677
15,558
0,4139
4,877
15,28
0,4136
36
It is not considered the last steam stream leaving the turbine since its pressure is even lower.
115
SINGLE-EFFECT
HOT
WATER-FIRED
CHILLERS: Carrier-Sanyo 16LJ
ABSORPTION
116
(Source: Carrier-Sanyo)
117
118
2 700 000
16LJ-53
2 700 000
16NK-81
6 200 000
16NK-71
5 300 000
16NK-41
3 000 000
8900
7568
5223
3624
2718
693
Figure A3. 2. Cooling demand load curve (2008) divided in periods according to
the power needed to be produced
119
Taking into account calculated percentages, cooling load during the year can
be estimated for the three production sites that are subject of studying:
37
Information from first column can be translated into percentages taking the maximum power as
reference.
120
A. LEAF
Table A3. 5. Cooling load to be produced and working power of different chillers (double- and single- effect) at LEAF during the year
NUMBER OF CHILLERS WORKING
COOLING
% of
& CAPACITY [kW]
POWER
TIME PERIOD
max.
PRODUCTION
power
TSA-16NK-81
TSA-16TJ-53
[kW]
15 November-15 March
7,79
895,45
3834
2300
2300
2300
2300
2300
Table A3. 6. Cooling power to be supplied to the chillers at LEAF during the year
COOLING OF CHILLERS free cooling- [kW]
TIME PERIOD
TSA-16NK-81
TSA-16TJ-53
15 November-15 March
121
Table A3. 7. Cooling load to be produced and working power of different chillers (double- and single- effect) at LEAF during the year
when the cooling demand is 10% higher than the estimated one
NUMBER OF CHILLERS WORKING
COOLING
% of
& CAPACITY [kW]
POWER
TIME PERIOD
max.
PRODUCTION
power
TSA-16NK-81
TSA-16TJ-53
[kW]
15 November-15 March
7,79
1012,7
100
13000
4334
4334
4334
2600
2600
2600
2600
2600
2600
Table A3. 8. Cooling power to be supplied to the chillers at LEAF during the year
when the cooling demand is 10% higher than the estimated one
COOLING OF CHILLERS free cooling- [kW]
TIME PERIOD
15 November-15 March
15 March-1 April & 1-15 November
April & 15 October-1 November
1-15 May & 15 September-15 October
15 May-15 June & 15 August-15 September
15 June-15 August
TSA-16NK-81
TSA-16TJ-53
7180,72
4787,75
4787,75
6900,36
6900,36
6665,22 6665,22 6665,22
7839,10 7839,10 7839,10
4847,72
4847,72
4312,89
4312,89
4312,89
4659,68
4659,68
4659,68
4659,68
5399,66
5399,66
5399,66
5399,66
5399,66
6349,66 6349,66 6349,66 6349,66 6349,66 6349,66
122
Table A3. 9. Cooling load to be produced and working power of different chillers (double- and single- effect) at LEAF
during the year when the cooling demand is 10% lower than the estimated one
NUMBER OF CHILLERS WORKING
COOLING
% of
& CAPACITY [kW]
POWER
TIME PERIOD
max.
PRODUCTION
power
TSA-16NK-81
TSA-16TJ-53
[kW]
15 November-15 March
7,79
779
100
10000
3334
3334
3334
2000
2000
2000
2000
2000
Table A3. 10. Cooling power to be supplied to the chillers at LEAF during the year
when the cooling demand is 10% lower than the estimated one
COOLING OF CHILLERS free cooling- [kW]
TIME PERIOD
15 November-15 March
15 March-1 April & 1-15 November
April & 15 October-1 November
1-15 May & 15 September-15 October
15 May-15 June & 15 August-15 September
15 June-15 August
TSA-16NK-81
TSA-16TJ-53
5523,91
7365,21
5308,57
5308,57
7690,78
7690,78
6030,35 6030,35 6030,35
3729,21
3729,21
4972,27
4972,27
4779,34
4779,34
4779,34
5192,07
5192,07
5192,07
5192,07
4884,36 4884,36 4884,36 4884,36 4884,36
123
B. MACKMYRA
Table A3. 11. Cooling load to be produced and working power of different chillers
(double- and single- effect) in Mackmyra production site during the year
NUMBER OF CHILLERS WORKING
COOLING
% of
& CAPACITY [kW]
POWER
TIME PERIOD
max.
PRODUCTION
power
TSA-16NK-81
TSA-16TJ-53
[kW]
15 November-15 March
7,79
389,33
Table A3. 12. Cooling power to be supplied to the chillers during the year and necessary cooling towers in Mackmyra production site
COOLING OF CHILLERS [kW]
TIME PERIOD
15 November-15 March
15 March-1 April & 1-15 November
April & 15 October-1 November
1-15 May & 15 September-15 October
15 May-15 June & 15 August-15 September
15 June-15 August
TSA-16NK-81
TSA-16TJ-53
TSA-16NK-81
TSA-16TJ-53
2762,12
3682,60
5306,86
7690,78
3729,21
4972,27
3582,68
3582,68
5192,07
5192,07
Capacity: 7691 kW
Flow: 1202,04 m3/h
Tmax. = 5,76 K
Capacity: 6010 kW
Flow: 572,4 m3/h
Tmax. = 9 K
Capacity: 4523 kW
Flow: 1202,04 m3/h
Tmax. = 3,39 K
Capacity: 6010 kW
Flow: 572,4 m3/h
Tmax. = 9 K
4522,14
4522,14
6010,2
6010,2
124
Table A3. 13. Cooling load to be produced and working power of different chillers (double- and single- effect) in Mackmyra
production site during the year when the cooling demand is 10% higher than the estimated one
NUMBER OF CHILLERS WORKING
COOLING
% of
& CAPACITY [kW]
POWER
TIME PERIOD
max.
PRODUCTION
power
TSA-16NK-81
TSA-16TJ-53
[kW]
15 November-15 March
7,79
428,45
100
5500
2750
2750
1833
1833
1833
Table A3. 14. Cooling power to be supplied to the chillers during the year and necessary cooling towers in Mackmyra
production site when the cooling demand is 10% higher than the estimated one
COOLING OF CHILLERS [kW]
TIME PERIOD
TSA-16NK-81
TSA-16TJ-53
15 November-15 March
15 March-1 April & 1-15 November
3038,69
4102,86
4051,59
5470,48
5838,63
4228,84
4228,84
15 June-15 August
4974,05
4974,05
Capacity: 5839 kW
Flow: 1202,04 m3/h
Tmax. = 4,37 K
3941,68
3941,68
5709,81
5709,81
4476,51
4476,51
TSA-16NK-81
4476,51
TSA-16TJ-53
Capacity: 5710 kW
Flow: 572,4 m3/h
Tmax. = 8,98 K
Capacity: 5710 kW
Flow: 572,4 m3/h
Tmax. = 8,98 K
Capacity: 4975 kW
Flow: 1202,04 m3/h
Tmax. = 3,72 K
Capacity: 4477 kW
Flow: 572,4 m3/h
Tmax. = 7,04 K
125
Table A3. 15. Cooling load to be produced and working power of different chillers (double- and single- effect)
in Mackmyra production site during the year when the cooling demand is 10% lower than the estimated one
NUMBER OF CHILLERS WORKING
COOLING
% of
& CAPACITY [kW]
POWER
TIME PERIOD
max.
PRODUCTION
power
TSA-16NK-81
TSA-16TJ-53
[kW]
15 November-15 March
7,79
350,55
100
4500
4500
2250
2250
Table A3. 16. Cooling power to be supplied to the chillers during the year and necessary cooling towers in Mackmyra
production site when the cooling demand is 10% lower than the estimated one
COOLING OF CHILLERS [kW]
TIME PERIOD
15 November-15 March
15 March-1 April & 1-15 November
April & 15 October-1 November
1-15 May & 15 September-15 October
15 May-15 June & 15 August-15 September
15 June-15 August
TSA-16NK-81
TSA-16TJ-53
2485,22
3313,62
4776,89
6920,26
8139,35
3355,55
4474,07
3226,12
3226,12
4671,87
4671,87
5494,90
5494,90
Capacity: 8140 kW
Flow: 1202,04 m3/h
Tmax. = 6,09 K
TSA-16TJ-53
Capacity: 5495 kW
Flow: 572,4 m3/h
Tmax. = 8,64 K
Capacity: 5495 kW
Flow: 572,4 m3/h
Tmax. = 8,64 K
126
C. JOHANNES
Table A3. 17. Cooling load to be produced and working power of different chillers in Johannes production site during the year
COOLING
TOTAL
POWER
% of max.
COOLING
NUMBER OF TSA-16LJ-53
PRODUCTION
TIME PERIOD
power for
POWER
CHILLERS WORKING
FOR
Hemlingby
PRODUCTION
& CAPACITY [kW]
HEMLINGBY
[kW]
[kW]
15 November-15 March
7,79
155,8
1555,8
NOTE: Cooling demand in Johannes represents the cooling needed for the turbine itself (to cool it
down because of friction energy generated by turbines axis and generator). Therefore, it is the
same all over the year, that is, it does not depend on the time period (outdoor temperature). This
way, cooling demand during the year has been estimated for Hemlingby shopping centers and
then, 1,4 MW for Johannes have been added up to each of them.
127
Table A3. 18. Cooling power to be supplied to the chillers during the year
and necessary cooling towers in Johannes production site
COOLING OF
COOLING TOWERS
TIME PERIOD
CHILLERS [kW]
NEEDED
15 November-15 March
Capacity: 4150 kW
15 March-1 April & 1-15 November
2455,47 2455,47
Flow: 858,24 m3/h
Tmax. = 8,70 K
April & 15 October-1 November
2701,99 2701,99
1-15 May & 15 September-15 October
15 May-15 June & 15 August-15 September
3141,34
3785,72
3141,34
3785,72
15 June-15 August
4149,40
4149,40
Capacity: 4150 kW
Flow: 858,24 m3/h
Tmax. = 8,70 K
Table A3. 19. Cooling load to be produced and working power of different chillers in Johannes production site
when the cooling demand is 10% higher than the estimated one
COOLING
TOTAL
POWER
% of max.
COOLING
NUMBER OF TSA-16LJ-53
PRODUCTION
TIME PERIOD
power for
POWER
CHILLERS WORKING
FOR
Hemlingby
PRODUCTION
& CAPACITY [kW]
HEMLINGBY
[kW]
[kW]
15 November-15 March
7,79
171,38
1571,38
128
Table A3. 20. Cooling power to be supplied to the chillers in Johannes production site during the year
when the cooling demand is 10% higher than the estimated one
COOLING OF
COOLING TOWERS
TIME PERIOD
CHILLERS [kW]
NEEDED
15 November-15 March
Capacity: 4394 kW
15 March-1 April & 1-15 November
2528,69 2528,69
Flow: 858,24 m3/h
Tmax. = 9,22 K
April & 15 October-1 November
2802,07 2802,07
1-15 May & 15 September-15 October
15 May-15 June & 15 August-15 September
3285,35
3990,75
3285,35
3990,75
15 June-15 August
4393,48
4393,48
Capacity: 4394 kW
Flow: 858,24 m3/h
Tmax. = 9,22 K
Table A3. 21. Cooling load to be produced and working power of different chillers in Johannes production site
when the cooling demand is 10% lower than the estimated one
COOLING
TOTAL
POWER
% of max.
COOLING
NUMBER OF TSA-16LJ-53
PRODUCTION
TIME PERIOD
power for
POWER
CHILLERS WORKING
FOR
Hemlingby
PRODUCTION
& CAPACITY [kW]
HEMLINGBY
[kW]
[kW]
15 November-15 March
7,79
140,22
1540,22
100
1800
3200
1600
1600
129
Table A3. 22. Cooling power to be supplied to the chillers in Johannes production site during
the year when the cooling demand is 10% lower than the estimated one
COOLING OF
COOLING TOWERS
TIME PERIOD
CHILLERS [kW]
NEEDED
15 November-15 March
Capacity: 3906 kW
15 March-1 April & 1-15 November
2379,80 2379,80
Flow: 858,24 m3/h
Tmax. = 8,19 K
April & 15 October-1 November
2601,92 2601,92
1-15 May & 15 September-15 October
15 May-15 June & 15 August-15
September
15 June-15 August
2997,33
2997,33
3575,81
3575,81
3905,32
3905,32
Capacity: 3906 kW
Flow: 858,24 m3/h
Tmax. = 8,19 K
130
16NK-81
chillers
COOLING TOWERS
LEAF
16TJ-53
chillers
16NK-81
chillers
MACKMYRA
16TJ-53
chillers
JOHANNES
16LJ-53
chillers
HEAT EXCHANGERS
(+FILTER)
-free cooling-
131
q1/q2 =n1/n2
P1/P2 = (n1/n2)3
where:
- q: fans air flow
- n: fans rotation speed (rpm)
- P: power
LEAF. Same heat exchangers have been considered for the three cases
since differences between the needed capacities are not so large and, in
addition, those equipments can work at 10% higher capacity than the
specified one.
MACKMYRA.
The
highest
capacity
between
required
cooling
JOHANNES. Cooling tower has been choosen so that it can cover the
cooling demand in the three cases, as the differences are not so large.
132
Figure A4. 1. Map of the city center with the main pipe that leaves LEAF production site and its length
133
It has been followed the same way for the main pipe as in the refrigerant
compression cooling project, since the production site and customers are the same
and, in addition, as necessary remarks for this decision have been already taken
into account.
134
Figure A4. 2. Map with the customers, pipes and distances for Mackmyra production site
135
136
Johannes
Figure A4. 3. Map with the customers for Johannes production site, pipe and its length
137
For this reason, the main distribution pipe is planning to be between all
these buildings. Once the pipe would leave the constructed area, it would go
through the forest, since its digging is cheaper than roads, and cross E4 highway
taking the advantage that it already exists a tunnel there. Thereafter, it would
reach the production plant as drawn because of the possibility of future customers
over there. Next Figure A4. 5. shows the future plan of the municipality of
building a new area close to Johannes CHP plant.
138
Figure A4. 5. Map of the future residential area close to Johannes plant
139
PRODUCTION
SITE
LEAF
1700
UNIVERSITY
TECHNOLOGIC
PARK
TOTAL
1800
4500
500
107,14
385,71
Mackmyra II
UNIVERSITY
1800
310
42,86
154,29
1700
Mackmyra III
HOSPITAL
TECHNOLOGIC
PARK
TOTAL
1890
64,29
231,43
1775
47,62
171,43
Mackmyra I
MACKMYRA
1000
1000
2700
HEMLINGBY
SHOPPING
2000
CENTERS
NOTE: Mass flow: P [kW] = m [kg/s] * Cp [kJ/kg K] * T [K] m = P/Cp/T
JOHANNES
Johannes
140
Appendix 5. Calculations about dimensions of pipes, distribution pumps and their costs
PRODUCTION
SITE
PIPES
LEAF
LEAF
PRESSURE
LOSS for
each pipe [Pa]
PRESSURE FOR
DISTRIBUTION
PUMP [Pa] 38
89050
328100
HOSPITAL
UNIVERSITY
TECHNOLOGIC
PARK
TOTAL
0,05
261,24
100
50000
25000
Mackmyra II
UNIVERSITY
0,02
165,22
175
54250
258500
Mackmyra III
HOSPITAL
TECHNOLOGIC
PARK
TOTAL
0,032
202,35
130
245700
641400
0,02
174,16
160
284000
718000
Mackmyra I
MACKMYRA
JOHANNES
Johannes
HEMLINGBY
SHOPPING
CENTERS
38
As the flow passes through pipes and other components in the system, the pressure decreases. Thus, it is needed a pressure difference in the system which is
generated in the pump and which is progressively dissipated by pressure losses in the distribution system with increasing distance from the pump. This is
shown in schematic Figure A5. 2.
141
Appendix 5. Calculations about dimensions of pipes, distribution pumps and their costs
NOTES:
- Diameter of pipes: = 2 (A/)
- The cross section of pipes has been calculated for a velocity of water flow of 2 m/s
(it is usually between 1 and 3 m/s for large pipes), for considering it the most
suitable (Greger Berglund).
The resistances have been calculated by using a SBI nomogram that can be seen in
the following page (Figure A5. 1.).
- Pressure increase that is needed (distribution pump) has been calculated considering
that there is a pressure drop of 150 kPa in the customer site (Greger Berglund),
although it is usually enough with 30-50 kPa safety margin-.
142
Appendix 5. Calculations about dimensions of pipes, distribution pumps and their costs
Figure A5. 1. SBI monogram showing the parameters of the different pipes
143
Appendix 5. Calculations about dimensions of pipes, distribution pumps and their costs
Nevertheless, they are not taken into consideration because of being very small.
There is only a temperature difference of 4C between the water that goes through
pipes and outside, so the resistances are therefore almost zero.
144
Appendix 5. Calculations about dimensions of pipes, distribution pumps and their costs
Going back to the diameter of pipes, outer diameters have been obtained
by using the following Table A5. 3. once internal diameters (see Table A5. 2.)
have been calculated.
Table A5. 3. PE Pressure Pipes for water supply: EN 12201, ISO 4427
(Source: PE Pressure Pipe Systems brochure)
145
Appendix 5. Calculations about dimensions of pipes, distribution pumps and their costs
A5.2. COSTS
A. DIGGING FOR PIPES AND TOTAL COSTS
The distribution system in ground looks like it is shown in Figure A5. 3..
Ground is dug and two pipes, forward and return ones, are introduced keeping the
distances (Greger Berglund) that can be observed in the figure. The hole is filled
with sand.
39
40
146
Appendix 5. Calculations about dimensions of pipes, distribution pumps and their costs
The values of parameters B and C from Figure A5. 3. depend on the outer
diameter, dn. Those are gathered in Table A5. 5.
Table A5. 5. Values of parameters C and B for the required dn
(Source: Greger Berglund, Gvle Energi AB)
dn [mm]
C [mm]
B [mm]
200
400
1000
250
450
1100
315
525
1250
NOTE: data for dn = 315 mm was missing, so the values have been interpolated
from the values of the original data and rounded off.
When pipes are going through water (as appropiate for LEAF), the
installation is totally different. Pipes are placed in the bottom of the river (or sea,
in other cases), keeping a distance of described C value between them. It would be
750 mm for LEAF pipes (dn = 450).
Next, costs of the main distribution system are shown, Table A5. 6.,
without taking into account the pumps.
LEAF
2500
147
Appendix 5. Calculations about dimensions of pipes, distribution pumps and their costs
Figure A5. 4. Distribution system cost split up in its components and their contribution to
the total cost
Finally, total costs of the distribution system except for the pumps can be
calculated:
PRODUCTION
SITE
LEAF
MACKMYRA
500
3 408
1 704 000
3 408 000
Mackmyra II
310
2 698
836 380
1 672 760
Mackmyra III
1 890
3 053
5 770 170
11 540 340
TOTAL
JOHANNES
TOTAL
COST
[SEK]
6 850 000
Johannes
1 775
16 621 100
2 698
4 788 950
9 577 900
148
Appendix 5. Calculations about dimensions of pipes, distribution pumps and their costs
B. PUMPS
Table A5. 8. Needed distribution pumps and their cost (Source: Zander & Ingestrm AB)
MAX.
PRODUCTION
Q 41
P
POWER PRICE
PUMP TYPE
SITE
[m3/h] [kPa]
CONS.
[SEK]
[kW]
KENFLO centrifugal
LEAF
771,43 328,1
77,4
110 000
pump, KPS 30-250
KENFLO centrifugal
MACKMYRA
317,14
250
27,5
62 000
pump, ISO 200x150-315
KENFLO centrifugal
JOHANNES
171,43
718
44,5
69 000
pump, ISO 100x65-250
41
Q: volumetric flow
149
A6.1. INSTALLATION
Figure A6. 1. Draft of the whole cooling installation in Falun (Source: Daniel Widman, Falu Energi & Vatten AB)
150
151
1 500 000
2 700 000
2 * 675 000
100 000
Maintenance costs are very low, so they are therefore not taken into
account. With regards to operational costs, they are calculated as sum of electric
power needed and water for cooling towers (it is assumed that steam is free). This
way, it is needed to assess costs for 250 kW plus 50 kW per each distribution
pump of electricity (1 SEK/kWh) and 10 m3/h of water (4 SEK/ m3).
5,84 kW 42
2 * 30,0 kW
184,16 kW
42
P = 7,3 kVA * 0,8 (power factor that most generators use) = 5,84 kW
152
Appendix 7.
EXTRA
INFORMATION
JOHANNES POWER PLANT
ABOUT
Johannes plant has a biofueled steam boiler, where there are mainly burnt
bark, forest residues and waste wood43. Nonetheless, it is needed oil to start up the
plant (which takes between 12 and 18 hours) and unfortunately, this fuel has to be
also sometimes used because of technical problems.
Next, basic scheme of the plant is shown in Figure A7. 1. for explaining
how it operates thereafter.
12
11
5
9
10
6
7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
FUEL INTAKE
SIEVING (fuel mixer)
FUEL STORAGE
CONVEYOR BELT FOR BIOFUEL UP TO THE BOILER
STEAM BOILER
DIRECT CONDENSER
TURBINE
VESSEL ACCUMULATORS
ELECTROSTATIC PRECIPITATOR
FLUE GAS CONDENSER (FGC)
CHIMNEY STACK
CONTROL ROOM
OIL TANK
AMMONIA TANK
4
13
3
14
2
Figure A7. 1. Scheme of Johannes CHP plant (Source: Gvle Energi AB)
The blending changes frecuently, which depends on the availability of different fuels, costs and
so forth.
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into a silo (sieving). Afterwards, the fuel mixture is put on a fuel storage building.
This place has a fuel capacity of a weekend production, since there is nobody
working on fulfilling it during this period.
Figure A7. 2. Fuel storage 44 and conveyor belt carrying biofuel to the boiler at Johannes
44
This picture was taken the 24th of March of 2009, when it was still winter. Despite the snow
and cold weather, biofuel keeps well since it is warm inside due to reactions (aerobic
decomposition of organic matter) that take place in there.
154
29 kg/s
94 bar
Figure A7. 3. Bubble Fluidized Bed (BFB) boiler of Johannes CHP plant
(Source: Gvle Energi AB)
The turbine called Olga was installed in 2005, which means that there
was previously a direct condenser instead that was used to cool down the steam by
means of district heating return water (it is still in there in case of a breakdown or
higher heating demands). It is a backpressure turbine, model Siemens SST-600,
which works in two steps and has a power output capacity of 22 MW (see
Figure A7. 4. and left side of Figure A7. 5.), where electricity is produced by
expanding and cooling the steam.
The exhaust steam leaving the turbine is then condensed in two heat
exchangers (see right side of Figure A7. 5.) and the water that extracts heat from
the steam goes to the supply pipe of the district heating network. When heat
supply is higher than the demand, hot water is stored, what there are two heat
accumulators for, and this way, it is delivered when the demand is higher
(compensation of load variations).
Characteristics of obtained electricity and water for district heating are
gathered in Table A7. 1.
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Turbine
Generator
Heat exchangers
Figure A7. 5. Olga turbine on the left side and heat exchangers on the right side. Johannes
CHP plant
156
condensation system (see Figure A7. 6. and for more specified information,
Figure A7. 7.). This waste heat is also used in the district heating network and
sand-ashes, together with the sand extracted from the bottom of the boiler and
cleaned in a rotational sieve, are recycled for reutilizing them in the boiler.
Figure A7. 6. Schematic of the FGC at Johannes (Source: Gvle Energi AB)