Energy Tips - Steam: Consider Installing High-Pressure Boilers With Backpressure Turbine-Generators
Energy Tips - Steam: Consider Installing High-Pressure Boilers With Backpressure Turbine-Generators
Energy Tips - Steam: Consider Installing High-Pressure Boilers With Backpressure Turbine-Generators
Background The capital cost of a backpressure turbogenerator complete with electrical switchgear varies from about $700/kW for a small system (50 kW) to less than $200/kW for a larger system (>2,000 kW). Installation costs vary depending upon piping and wiring runs, but typically average 75% of equipment costs. Packaged or off-the-shelf backpressure turbogenerators are now available in ratings as low as 50 kW. Backpressure turbogenerators should be considered when a boiler has steam flows of at least 3,000 lbs/hr, and when the steam pressure drop between the boiler and the distribution network is at least 100 psig. The backpressure turbine is generally installed in parallel with a PRV, to ensure that periodic turbine-generator maintenance does not interfere with plant thermal deliveries.
Steam Tip Sheet information is adapted from material provided by TurboSteam Corporation. For additional information on steam system efficiency measures, refer to Steam Tip Sheet No. 20 Replace Pressure-Reducing Valves with BackPressure Turbogenerators and the Steam System Basics: End Use section of Improving Steam System PerformanceA Sourcebook for Industry. These materials are available from the EERE Information Center at 1-877-337-3463.
200
50
0 100 200 300 400 500 600 700 800 Input Pressure (psig)
Note: Assumes 50% isentropic turbine efficiency, a 96% efficient generator, and dry unsaturated inlet steam.
Example
A chemical company currently uses a 100-psig boiler with 78% boiler efficiency (boiler) to produce 50,000 pounds per hour (lb/hr) of saturated steam for process loads. The plant operates two shifts per day, with the boiler operating at rated capacity for 6,000 hours/year. The boiler has reached the end of its service life and the company is considering replacing the boiler with a new 100-psig boiler or with a high-pressure 600-psig boiler and a backpressure steam turbine-generator. Both new boiler alternatives have rated efficiencies of 80%. The company currently pays 6 cents/kWh for electricity, and purchases boiler fuel for $5.00/MMBtu. Condensate return to the boiler has an enthalpy of 150 Btu/lb. What are the relative financial merits of the two systems?
Step 1: Calculate the current annual boiler fuel cost = $2,000,000 per year Current boiler fuel cost = [fuel price] x [steam rate] x [annual operation] x [steam enthalpy gain] / [boiler] = $5.00/MMBtu x 50,000 lb/hr x 6,000 hrs/yr x (1,190 Btu/lb 150 Btu/lb) /0.78 = $2,000,000 per year Step 2: Calculate the boiler fuel cost of a new 100-psig low-pressure (LP) boiler = $1,950,000 per year Resulting reductions in fuel costs are due solely to the higher efficiency of the new boiler. New LP boiler fuel cost = [fuel price] x [steam rate] x [annual operation] x [steam enthalpy gain] / [boiler] = $5.00/MMBtu x 50,000 lb/hr x 6,000 hrs/yr x (1,190 Btu/lb 150 Btu/lb) /0.80 = $1,950,000 per year Step 3: Calculate the boiler fuel cost of a new high-pressure (HP) boiler capable of producing 600-psig, 750F superheated steam = $2,073,940 per year We must now take into account the additional enthalpy necessary to raise the pressure of the boiler steam to 600-psig. With a 50% isentropic turbine efficiency, the exhaust steam from the backpressure turbine is at 100-psig and 527F and must be desuperheated. In order to provide an equivalent amount of thermal energy to the process loads, the boiler steam output is reduced to 45,000 lbs/hour. New HP boiler fuel cost = [fuel price] x [steam rate] x [annual operation] x [steam enthalpy gain] / [boiler] = $5.00/MMBtu x 45,000 lb/hr x 6,000 hrs/yr x (1,379 Btu/lb 150 Btu/lb) / 0.80 = $2,073,940 per year Step 4: Estimate the electricity output of the steam turbine-generator = 6,750,000 kWh/year At 600-psig inlet pressure with 750F superheated steam and 100-psig exhaust pressure, the system will satisfy existing steam loads, but will also produce approximately 25 kW of electric power per Mlb/hour of steam production (Refer to Figure 1 to estimate your power output for steam at saturated conditions). Thus, Turbine-generator power output = 45 Mlb/hour x 25 kW/Mlb/hour = 1,125 kW Assuming a 6,000-hour operating year, the electricity output of this turbine will be: Turbine-generator electricity output = 1,125 kW x 6,000 hours/year = 6,750,000 kWh/year Step 5: Determine the cost of electricity produced by the turbine = $0.018/kWh The value is derived from the difference in fuel costs between the two boiler alternatives, divided by the power produced by the turbine: Fuel cost of produced electricity = [$2,073,940/year - $1,950,000/year] / 6,750,000 kWh/year = $0.018/kWh Step 6: Calculate energy savings benefits = $283,500 per year Cost savings = 1,125 kW x ($0.06/kWh $0.018/kWh) x 6,000 hours per year = $283,500 per year This level of savings is often more than adequate to justify the capital and maintenance expenditures for the backpressure turbine-generator set and the incremental cost of purchasing and installing the higherpressure boiler.
Suggested Actions Consider installation of a high-pressure boiler with a backpressure turbinegenerator whenever undertaking a boiler upgrade. When evaluating this opportunity, you should: Determine how much steam enthalpy, pressure and temperature is required at the header downstream from your boiler. Calculate the incremental fuel cost between a low-pressure boiler and a high-pressure boiler. Develop steam flow/duration curves for your boiler. (Remember that electrical generation will follow your steam load or process heating requirements). Obtain plant electricity and fuel cost information. Use the tools provided in this fact sheet to estimate your electricity generation potential and to determine savings from purchasing and installing a high-pressure boiler plus a backpressure turbine-generator set.
BestPractices is part of the Industrial Technologies Program Industries of the Future strategy, which helps the countrys most energy-intensive industries improve their competitiveness. BestPractices brings together emerging technologies and best energy-management practices to help companies begin improving energy efficiency, environmental performance, and productivity right now. BestPractices emphasizes plant systems, where significant efficiency improvements and savings can be achieved. Industry gains easy access to near-term and long-term solutions for improving the performance of motor, steam, compressed air, and process heating systems. In addition, the Industrial Assessment Centers provide comprehensive industrial energy evaluations to small- and medium-size manufacturers.
FOR ADDITIONAL INFORMATION, PLEASE CONTACT: EERE Information Center 1-877-EERE-INF (1-877-337-3463) www.eere.energy.gov Industrial Technologies Program Energy Efficiency and Renewable Energy U.S. Department of Energy Washington, DC 20585-0121 www.eere.energy.gov/industry