16.02.2016 A QUANTUM LEAP The biggest change in energy efficiency since the shift from steam to diesel propulsion machinery Jon Åge Eidem, Ulmatec 16.02.2016 ULMATEC � Ulmatec Handling Systems AS, Hareid, Norway � Ulmatec Components AS, Hareid, Norway � Ulmatec Skipsservice AS, Fosnavåg, Bergen, Tromsø, Norway � Ulmatec Pyro AS, Gamlem, Norway � Ulmatec Engineering AS, Hareid, Norway � Ulmatec Baro AS, Fosnavåg, Norway � Penetrators Norge AS, Stavanger-Ulsteinvik, Norway � Penetrator Inc. Canada, North America � Ulmatec Asia Pte Ltd Singapore � Ulmatec Well Products As, Stavanger, Norway � Powder Tec AS, Surnadal, Norway � Ulmatec Services LLC Dubai, UAE � Ulmatec Baro LLC Houston, North America 4 1
16.02.2016 16.02.2016 MORE THAN 60 YEARS OF KNOW-HOW Pyro founder Palmar Bjørnøy Cold trips to Shetland – 1940 - 1945 5 16.02.2016 MORE THAN 15.000 SHIPS WORLDWIDE WITH PYRO™ HEATING SYSTEMS 6 2
16.02.2016 16.02.2016 ÅRETS BEDRIFT MØRE OG ROMSDAL 2014 ÅRETS NYSKAPAR NORDVESTLANDET 2015 7 16.02.2016 Our focus and promise since 2011 … recovering otherwise wasted energy instead of using high- grade energy in the form of oil or gas 8 3
16.02.2016 16.02.2016 In 2011 we claimed ONLY 30-40% OF ENERGY 60% OF ENERGY IS USED EFFICIENTLY CAN EASILY BE UTILISED 9 16.02.2016 Now, in 2015, we know that CAN BE UTILISED 10 4
16.02.2016 16.02.2016 PYRO™ WASTE ENERGY MANAGEMENT SYSTEM A QUANTUM LEAP � Steam engine The most important energy saving 1800 - 10-15% efficiency / utilisation invention since moving from � Diesel engine 1900 - 30-40% efficiency / utilisation steam engine to diesel engine � Diesel Engine + Waste Heat Recovery 2011* - 40-60% efficiency / utilisation � Diesel Engine + Waste Energy Management 2015** - 60-75% efficiency / utilisation * In 2011 Ulmatec Pyro introduced the Pyro™ Waste Heat Recovery System ** In 2015 Ulmatec Pyro introduced the Pyro™ Waste Energy Management System 11 16.02.2016 RUN YOUR HEATING, COOLING AND POWER SYSTEMS AT MINIMUM COST We see a great many opportunities for huge savings by transferring energy consumption from electricity to waterborne heat… … even generating electric power from waste heat recovery 12 5
16.02.2016 16.02.2016 MADE POSSIBLE WITH PYRO™ SYSTEMS Traditional products � Fuel Fired Heater � Exhaust gas Economiser � Incinerator System New products 2012-2013 � Waste Energy Recovery System (patent) � Tank Heating System (patent) 13 16.02.2016 MADE POSSIBLE WITH... GREEN TECHNOLOGY from ULMATEC, SPERRE & ANDA OLSEN � SPERRE Pleat & Rack Coolers with their uniqe competence and low pressure drop. � ANDA OLSEN battery technology for energy storage and peak operations together with CLIMEON New products 2015-2017 � De-Icing System (patent) � Ballast Water Management System (patent) � Waste Energy Cooling System (patent) � Waste Energy Power Generation System (patent) � Waste Energy Management System (patent) 14 6
16.02.2016 16.02.2016 UNDERSTANDING THE ENERGY CONVERSION Caterpillar 3516C (data from engine supplier) kW 2500 Rated power 36,6 % 830 Heat rejection to coolant 12,2 % Heat rejection to exhaust gas 2478 36,3 % 59,7 % Heat rejection to charge air aftercooler 763 11,2 % Heat rejection to air from engine 161 2,4 % Heat rejection to air from generator 91 1,3 % Total effect 6823 100,0 % Fuel consumption L/h kg/h kg/kWh Engine load 100 % 656 564,16 0,226 Engine load 75 % 510 438,60 0,234 Engine load 50 % 372 319,92 0,256 Fuel energy kW Load 6823 Fuel energy KJ/s (kW) 43539 100 % Max. Specific Fuel value KJ/kg 45000 Energy Cost NOx kg/year Effekct Energy/24h Consumption Nox Fuel Cost kW kwh kg/kWh *3) kg/kg *1) USD/kg *2) USD/liter kg/liter KJ/kg NOx tax USD Fuel USD Total USD Engine < 200 rpm (Generator) 1250 30000 0,256 0,1000 2,40 0,86 43539 672 768 - 672 768 280 320 Engine 200-1000 rpm (Generator) 1250 30000 0,256 0,0530 2,40 0,60 0,86 43539 356 567 1 955 721 2 312 288 148 570 Engine 1000-1500 rpm (Generator) 1250 30000 0,256 0,0500 2,40 0,60 0,86 43539 336 384 1 955 721 2 292 105 140 160 Engine >1500 rpm (Generator) 1250 30000 0,256 0,0440 2,40 0,60 0,86 43539 296 018 1 955 721 2 251 739 123 341 Fuel fired heater (MGO) 1250 30000 0,091 0,0036 2,40 0,60 0,86 43539 8 609 695 198 703 807 3 587 Heat recovery 1250 30000 - - - - *1)= kg Nox / kg fuel Engines (200-1000kW og >1500kW) before year 2000, Nox value increase 0,001 kg/kg *2)= USD/ kg. Nox (19,19NOK/8,00USD/NOK=2,40 USD/kg) *3)= Engine speciffic values to be used (e.g. 0.256 g/kWh) 15 *4)= Spesiffic density MGO 0,86 kg/liter 16.02.2016 FUEL SAVINGS Offshore Vessel 120mx22m Engine Installation 5xCaterpillar 3516C 12500 kW Average Engine load 2x50% 2500 Available Waste Energy effect @ 100% engine load 3200 kW Actual available Waste Energy effect @ 50% engine load 1250 kW Crew 120 Ballast Water capasity 5000 m3 Installed cooling effect 15000 kW Operational hours 8760 h Energy efficiency 0,256 kg/kwh Desity fuel 0,86 kg/liter Avearage consumption/year Tropical Area Northern Area Artic Area Effect kW Energy kWh Effect kW Energy kWh Effect kW Energy kWh Heating of accomodation 0 - 150 1 314 000 250 2 190 000 Cooling of accomodation 150 1 314 000 50 438 000 0 - Fresh Water Production 200 1 752 000 300 2 628 000 400 3 504 000 Sanitary Hot Water 25 219 000 45 394 200 50 438 000 Tank Heating - - - Tank Washing - - - De-Icing - - 1000 8 760 000 Ballast Water Treatment - - - Pre-heating of engine at standstill 25 219 000 40 350 400 50 438 000 Total waste energy used 400 3 504 000 585 5 124 600 1750 10 950 000 Fuel Fired Energy 500 4 380 000 Available waste energy 850 665 0 Electricity production 10% efficiency 85 744 600 66,5 582 540 0 - Fuel savings (Liter) 1 264 700 1 698 870 1 955 721 Total Fuel Consumption (Liter) 6 519 070 6 519 070 6 519 070 Total Fuel Saving 19 % 26 % 30 % 16 7
16.02.2016 16.02.2016 Example of benefits REDUCED PUMP EFFECT = 2000 LITRE FUEL/YEAR Marine gas oil price is going up and down. Currently the cost is about US$500 per tonne and has been up to US$ 960 per tonne, but is expected to increase toUS$1,800 by 2020, and to US$2,300 by 2035 Source: Article by Chad Henderson, Wallenius Wilhelmsen Logistics, October 2014. Adjusted for current prices (September 2015). 17 16.02.2016 PYRO™ WASTE ENERGY COOLING SYSTEM 1 2 3 4 Fixed rpm Frequency controlled Frequency controlled Fixed rpm 18 8
16.02.2016 16.02.2016 PYRO™ WASTE ENERGY COOLING SYSTEM FUEL SAVING: 800.000 kWh = 200.000 LITRE FUEL/YEAR Example Traditional WECS � Cooling effect: 15.000 kW 15.000 kW � Pump capacity: 4x800m3/h 6x400m3/h � Pumping effect: 4x100 kW 6x50 kW � Energy Consump. 2 pumps: 1.600.000kWh 800.000kWh 19 PLATE HEAT EXCHANGER SPERRE PLEAT COOLER (PHE) 240 MAN-HOURS 1 MAN-HOUR 45 GASKETS 50 DAYS OFFHIRE 1 GASKET 1 DAYS OFFHIRE 9
16.02.2016 Energy saving solution Fuel savings - Emission reductions Reduced energy consumption on the seawater-pumps due to low pressure drop Rack cooler have no marine growth due to CuNi 90/10 and antifouling paint Chilled water element reduces running time at the chilled-water compressors Heat recovery element makes it possible to use the surplus heat 16.02.2016 PYRO™ WASTE ENERGY COOLING SYSTEM 4 Fixed rpm REDUCED PUMP EFFECT = 200.000 LITRE FUEL/YEAR Four pumps with automatic regulated valves which only pumps the required volume and flow of cooling water. Reduced number of pumps saves energy. A flexible system that works. 22 10
16.02.2016 16.02.2016 PYRO™ COOLING SYSTEM BENEFITS � Reduced no. of cooling pumps installed � Reduced no. of cooling pumps running � Full control of cooling temperatures � Reduced no. of heat exchangers installed � Full control of circulation pressure � Possible to utilize the waste low temperature (LT) cooling energy � Full flexibility in no. of cooling pump running (automatic start/stop) � Less energy used for cooling water circulation � Monitoring the waste energy utilized - and wasted to sea and air (exhaust) 23 16.02.2016 PYRO™ WASTE ENERGY MANAGEMENT SYSTEM CASE STUDY – INSTALLATION 140m Offshore Construction Vessel DP3-4 split power system � No. of seawater (SW) cooling pumps reduced from 30 to 12 reduction = 18 � No. of freshwater (FW) cooling pumps reduced from 26 to 12 reduction = 14 � No. of seawater heat exchangers reduced from 20 to 8 reduction = 12 � No. of freshwater heat exchangers increase from 0 to 4 increase = 4 � A minimum of cooling pumps running according to cooling requirement In DP mode: 2-8 SW cooling pumps + 2-8 FW cooling pumps running Normal mode: 1-8 SW cooling pumps + 1-8 FW cooling pumps running � Full flexibility and back-up capacity � DNV GL verified solution � Significant reduction in engineering time � Significant reduction in installation time � Standardised and modulated “plug and play” units 24 11
16.02.2016 PYRO™ WASTE ENERGY POWER GENERATION SYSTEM EGB EMISSION-FREE HT circuit ELECTRICITY 85C-95C Cooling water 0C – 35C Product range from 150kWe to 600kWe 25 16.02.2016 PYRO™ WASTE ENERGY POWER GENERATION SYSTEM 1300kW WASTE ENERGY ELECTRIC POWER 26 12
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