Uncategorized
Waste Incineration
Capitalising on available steam from incineration processes
The Heliex GenSet offers waste incineration plants an efficient way to generate electricity from the heat energy in incinerator flue gasses, while complying with emissions controls.
Working with the UK’s leading waste service providers, Heliex has developed an in-depth understanding of this global industry, its processes and how clients in this sector can increase profitability thanks to our patented technology.
By integrating a Heliex system into their exisiting steam system our customers can benefit from an attractive return on investment, security of supply and improved environmental impact.
A Good Fit
Incineration at high temperatures means lots of potential for energy recovery. The resultant flue gases need to be cooled before being treated and provide an excellent means of raising steam. The Heliex GenSet is an ideal solution for waste incinerators because:
- It utilises the steam that would otherwise be wasted
- It can accept the varying steam loads resulting from differing waste products
- As the demand varies, any steam not required for export for additional revenue will be used on site for electrical generation.
Recent Projects:
| Industry: Waste Incineration | Power: 160 kWe |
| Country: The UK’s leading healthcare waste specialists | Model: HP204 |
| Customer Profile: Waste Heat Recovery | |
| Country: UK |
Our client operates a number of sites across the UK where clinical waste is incinerated at temperatures of as high as 1000°C. They have installed Heliex GenSets at two of their facilities, with plans to roll out to a further seven by 2018.
The first installation was at their facility in the North of England. A Heliex GenSet was incorporated into the existing process for cooling the incineration flue gases. A waste heat steam boiler is used to absorb the heat from the incineration flue gases to heat water, which is turned into steam.
This steam goes through the Heliex GenSet, where it generates electricity, before being condensed to water and then returned to the waste heat boiler to start the process again.
The estimated value to our customer, based on supply and install costs:
| Electrical value per year: £110,000 | C02e savings: 700 tonnes/CO2e |
| Electrical fan saving: £11,000 | Years until payback: 2 |
| Total savings per year: £121,000 |
| Industry: Waste Incineration | Power: 84 kWe |
| Country: The UK’s leading healthcare waste specialists | Model: HP145 GenSet |
| Customer Profile: Waste Heat Recovery | |
| Country: UK |
The newly installed waste heat recovery system involved the integration of two waste heat recovery boilers generating up to 5 t/h of steam, at a boiler pressure of 15 barg being reduced via a Pressure Reduction Valve (PRV) to an autoclave inlet pressure of 5 barg.
The Heliex GenSet was installed as a part of a newly developed, state of the art, £10m facility that will recycle and use Scotland’s medical waste as an energy source. The Heliex GenSet will generate electricity to improve the overall performance of the plant.
The estimated value to our customer, based on supply and install costs:
Electrical savings per year: £57,000
C02e savings: 352 tonnes/CO2e
Years until payback: 3
Steam Expander Generator Set HP145
Description
The HP145 steam expander generator set is a fully integrated system which converts energy in the form of wet steam into clean electrical power.
Features
- Rugged screw expander technology
- Standalone packaged unit
- Industry standard key components
- Fully automated
Package design may vary.
| Performance | HP145 – 90 | HP145 – 110 | HP145 – 132 | HP145 – 160 |
| Gross power output * | Up to 90 kWe | Up to 110 kWe | Up to 132 kWe | Up to 160 kWe |
| Auxiliary power input | Up to 2.5 kWe | Up to 2.5 kWe | Up to 2.5 kWe | Up to 2.5 kWe |
*Depending upon steam inlet and outlet conditions. 75kWe rating available on demand.
| Operating parameters | ||
| Electrical | 400V, 50Hz, 3ph+N | 480v, 60Hz, 3ph+N Option |
| Ambient temperature | -10°C to +45°C | |
| Ambient humidity | <95% (non-condensing) | |
| Installation | Indoor or Outdoor | |
| Sound pressure level | ||
| Steam mass flow rate range | Up to 5000kg/h | |
| Max. steam inlet temperature | 221°C (saturated steam) | |
| Max. steam inlet pressure | 23.5 Bar A | |
| Max. inlet-outlet ΔP | 15 Bar | |
| Steam inlet dryness fraction | <97% | |
| Dimensions and foundations | |
| Dimensions | 2750 X 1700 X 2000mm (LWH) |
| Mass | Up to 3,500 kg depending upon electrical generator rating |
| Lifting and handling | Standard forklift pockets 200 x 100 mm, 1300 mm between centres |
| Site foundation | Level load bearing surface 3000 x 2000 mm |
Heliex Power Ltd reserve the right to change technical specification without notice
Steam Expander Generator Set HP204 up to 400kW
Description
The HP204 steam expander generator set is a fully integrated system which converts energy in the form of wet steam into clean electrical power.
Features
- Rugged screw expander technology
- Standalone packaged unit
- Industry standard key components
- Fully automated
Package design may vary.
| Performance | HP204 – 160 | HP204 – 250 | HP204 – 315 | HP204 – 400 |
| Gross power output | Up to 160 kWe | Up to 250 kWe | Up to 315 kWe | Up to 400 kWe |
| Auxiliary power input | Up to 2.5 kWe | Up to 2.5 kWe | Up to 2.5 kWe | Up to 2.5 kWe |
*Depending upon steam inlet and outlet conditions. 75kWe rating available on demand.
| Operating parameters | ||
| Electrical | 400V, 50Hz, 3ph+N | 480v, 60Hz, 3ph+N Option |
| Ambient temperature | -10°C to +45°C | |
| Ambient humidity | <95% (non-condensing) | |
| Installation | Indoor or Outdoor | |
| Sound pressure level | ||
| Steam mass flow rate range | 1800kg/h to 13500kg/h | |
| Max. steam inlet temperature | 221°C (saturated steam) | |
| Max. steam inlet pressure | 23.5 Bar A | |
| Max. inlet-outlet ΔP | 20 Bar | |
| Steam inlet dryness fraction | <97% | |
| Dimensions and foundations | |
| Dimensions | 3000 X 1850 X 2000 mm (LWH) |
| Mass | Up to 9,000 kg |
| Lifting and handling | Standard forklift pockets 180 x 80 mm, 1300 mm between centres |
| Site foundation | Level load bearing surface 3500 X 2500 mm |
| Plant services and interconnections | |
| Steam inlet | DN100, PN25 |
| Steam outlet | PN25 flange and depending on customer steam flow either DN150,200,250 or 300 |
| Compressed air supply | 7 bar g (Instrument air to ISO 8573.1 Class 2:3:1) |
| Electrical output | 400V, 3 ph+N, continuous rating to suit generator protection device |
| Electrical input | 400V, 3 ph+N |
| Remote monitoring | Internet bridge (via internet cable or optional wireless GPRS / UMTS Modem). BMS or SCADA systems – MODbus over RS232, RS485, USB, Ethernet. |
Steam Expander Generator Set HP204 500kW & 630kW
Description
The HP204 steam expander-generator set is a fully integrated system which converts energy in the form of wet steam into clean electrical power.
Features
- Rugged screw expander technology
- Standalone packaged unit
- Industry standard key components
- Fully automated
- Soft start
| Performance | HP204 – 500 | HP204 – 630 |
| Gross power output | Up to 500 kWe | Up to 630kWe |
| Auxiliary power input | Up to 2.5 kWe | Up to 2.5 kWe |
| Operating parameters | ||
| Electrical | 400V, 50Hz, 3ph+N | 480v, 60Hz, 3ph+N Option |
| Ambient temperature | -10°C to +45°C | |
| Ambient humidity | <95% (non-condensing) | |
| Installation | Indoor or Outdoor | |
| Sound pressure level | ||
| Steam mass flow rate range | 1800kg/h to 13500kg/h | |
| Max. steam inlet temperature | 221°C (saturated steam) | |
| Max. steam inlet pressure | 23.5 Bar A | |
| Max. inlet-outlet ΔP | 20 Bar | |
| Steam inlet dryness fraction | <97% | |
| Dimensions and foundations | |
| Dimensions | 3000 X 1850 X 2000 mm (LWH) |
| Mass | Up to 9,000 kg |
| Lifting and handling | Standard forklift pockets 180 x 80 mm, 1300 mm between centres |
| Site foundation | Level load bearing surface 3500 X 2500 mm |
| Plant services and interconnections | |
| Steam inlet | DN100, PN25 |
| Steam outlet | PN25 flange and depending on customer steam flow either DN150,200,250 or 300 |
| Compressed air supply | 7 bar g (Instrument air to ISO 8573.1 Class 2:3:1) |
| Electrical output | 400V, 3 ph+N, continuous rating to suit generator protection device |
| Electrical input | 400V, 3 ph+N |
| Remote monitoring | Internet bridge (via internet cable or optional wireless GPRS / UMTS Modem). BMS or SCADA systems – MODbus over RS232, RS485, USB, Ethernet. |
Chemical Manufacturing
The global chemicals industry is one of the world’s largest energy consumers, with energy efficiency high on the agenda and significant savings to be made.
Most chemical production sites utilise steam, which is frequently used in processes and offers many opportunities for the installation of a Heliex steam expander or compressor System.
By integrating a Heliex system into their exisiting steam system our customers can benefit from an attractive return on investment, security of supply and improved environmental impact.
You can:
- Generate electricity with a Heliex Genset
- Produce compressed air with a Heliex AirComp
- Drive a piece of machinery with a Heliex SteamDrive
- Re-energise your process steam with a Heliex SteamComp
A Good Fit
The high temperatures and significant amounts of steam required in the chemical industries results in many opportunities for energy recovery.
The Heliex steam expander or compressor stem is an excellent solution for the chemicals industry because:
- Wet steam can be used without damage to the machine
- A range of steam pressures and varying flowrates can be accommodated
- It is an excellent utilisation of excess steam that may otherwise be wasted
- Installed in parallel with an existing Pressure Reduction Valve (PRV) it does not interfere with the production process
- The packaged machine is a simple plug and play installation
| Industry: Chemicals | Power: 2 x 123 kWe |
| Customer Profile: Global Speciality Chemicals Company | Model: 2 x HP145 Heliex Gensets |
| Application: Pressure Reduction Valve (PRV) | |
| Country: UK |
Committed to sustainable development, our client investigated how to exploit the energy in their process steam.
Two Heliex HP145 GenSets were installed in parallel with the Pressure Reduction Valve (PRV) in the existing steam distribution system. This delivers significant economic benefits, while having two systems allows for additional operational flexibility.
Our client enjoys carbon saving of 348 tonnes CO2e and financial savings of an estimated £122,000 each year, with a payback of under 3 years.
Recent Projects:
| Industry: Chemicals | Power: 120 kWe |
| Customer Profile: Poland’s largest chemicals company | Model: HP204 Heliex Genset |
| Application: Pressure Reduction Valve (PRV) | |
| Country: Poland |
Our client, one of Europe’s leading chemicals manufacturers, is involved in chemical processing and plastics for the agricultural and construction industries.
Looking to further increase sustainability and efficiency, they recently installed a Heliex HP204 GenSet into their existing steam distribution system.
They use a large amount of low pressure steam at 6 barg, which formerly went through a PRV to atmosphere. Now the steam is rerouted through the Heliex GenSet, where the pressure is dropped and a supply of electricity is generated, before being vented.
Our client now benefits from a low cost source of electricity for use on site simply by utilising a steam supply that would otherwise have been wasted.
Biomass
Install a Heliex GenSet and use the steam from your biomass boiler to generate electricity and provide heat for your process needs. Enjoy a significantly shorter payback on your project and a typical return on the Heliex GenSet of just one year.
Turning up the heat on your investment
If you’re in the UK then payments from the government’s Renewable Heat Incentive (RHI) will increase significantly as you will qualify for a higher Combined Heat and Power (CHP) tariff. Your system may also be eligible for payments through Renewable Obligation Certificates (ROC’s) a financial support mechanism for UK renewable electricity projects.
Drop the pressure
The Heliex GenSet is installed after the biomass boiler where it drops the steam pressure and extracts energy from the steam to generate electricity. After the Heliex GenSet the steam can be used for a process such as heating, drying, cooling, hot water, space or district heating.
Compatible with fluctuating flows
A key feature of the Heliex GenSet is that it works well with fluctuating steam flows, adapting and continuing to generate electricity even when the heat demand is low, for example during the summer months.
Recent Projects:
| Industry: Nursery | Power: 132kW |
| Country: UK | Model: HP145 |
| Customer Profile: AMP plc/Villa Nursery |
1.65 MW Combined Heat and Power (CHP) biomass facility at Villa Nursery in Essex, will result in vastly reduced energy bills for the family business that supplies salad to some of the UK’s largest supermarkets including Waitrose and Aldi.
In the project, fully financed by AMP plc, the Heliex GenSet has been installed alongside a steam raising biomass boiler to form an impressive new steam generating CHP facility. This will form part of the Villa Nursery’s sustainable development programme over the next 20 years.
| Industry: District Heating | Power: 132kW |
| Country: Austria | Model: HP145 |
| Customer Profile: Municipal utility company generating heat and power for local users |
4MW biomass boiler is used to generate steam feeding a brewery and the local district heating in this picturesque village close to Salzburg. High pressure steam out of the boiler is directly delivered to the brewery while the remaining steam is reduced in pressure via the Heliex HP145 GenSet before feeding the heat exchanger generating hot water for the local district heating network.
The retrofit of the Heliex unit into the existing boiler house ensures the entire system is eligible for government incentives in the form of Feed In Tariff (FIT) on the electrical power generated, which make the project economics very attractive for the customer allowing a payback time of around 2.5 years.
STEAM AUXILIARY EQUIPMENT
- Steam traps
- Inverted bucket
- Rifox Rotary Traps
- Ball float & Thermostatic Steam Traps
- Thermodynamic Steam Traps
- Balanced pressure Thermostatic Steam Trap & Air vents
- Pressure reducing valves
- Air eliminators and liquid drainers
- Steam seperators
TC Wilson
Thomas C. Wilson is a smart source for all your tube expanders, tube cleaners, and HVAC maintenance equipment for heat exchangers, boilers, condensers, and pipes.
Subzero
Subzero Tube Tools Pvt Ltd, made its mark in the market as one of the leading manufacturers, exporters and suppliers of this highly commendable range of Tubes, Bolting Tools and Hydraulic Systems. The offered range, comprises the finest Tube Or Stub Pulling Systems, Bolting Tools and Tube Expansion Systems, having a high preference in the market. Manufacturing of this range is done as per the set industry norms and guidelines, utilizing the finest raw materials and modern machines. This ensures the product’s performance, capacity, strength and service life. In addition to this, the range is quite reasonably priced.