Cogeneration Steam Production Energy Optimization
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Solution Overview
Problem
Current industrial sites face inefficiencies in energy and heat production, as existing cogeneration and steam production units do not effectively optimize energy efficiency, leading to suboptimal use of resources and increased consumption of steam.
Innovation Solution
Integration of a cogeneration unit with a heat recovery boiler and an adjacent steam production unit, where air is preheated through heat exchange with water from the cogeneration unit, and water is heated using steam from both units, optimizing energy transfer and reducing steam consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If air is preheated by heat exchange with water from the cogeneration unit, then steam consumption is reduced, but the temperature difference between water and air must be maintained at least 20°C
Solution Approach 1:
A heat exchanger is introduced as an intermediary device between the water from the cogeneration unit and the air to be preheated. This mediator enables efficient heat transfer while maintaining the required temperature difference of at least 20°C, allowing steam consumption to be reduced by 10% without compromising the thermal requirements of either stream.
2Use of energy by moving object
If water is heated by steam from both cogeneration and steam production units, then energy efficiency is optimized, but system complexity increases
Solution Approach 1:
The patent merges the steam supply systems from both the cogeneration unit and the steam production unit into a single integrated water heating process. By combining these two steam sources to heat the water that will later preheat the air, the system optimizes energy utilization across both units while managing the inherent complexity through unified process integration.
3Productivity
If heat recovery unit processes more water to maintain steam production, then steam output is maintained, but energy transfer requirements increase
Solution Approach 1:
The system performs preliminary heating of the water feed to the heat recovery unit by utilizing steam from both the cogeneration and steam production units. This preheating action reduces the energy transfer burden on the heat recovery unit itself, allowing it to maintain steam production levels more efficiently while reducing overall steam consumption by 10%.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces steam consumption by 10% while maintaining steam production levels, enhancing overall energy efficiency and resource utilization without significant drops in heat recovery unit output.
Implementation Method 1
the heating of water (6) by the combustion gases (4) of the gas turbine (1) in the heat recovery unit (5)
Implementation Method 2
the heating of water (12) by combustion of a fuel (11) and air (10) in the steam production unit (B)
Implementation Method 3
preheating of said air (10) carried out at least in part by heat exchange with said water (6)
Data Source
Figure 1
AI summary
A process for the production of energy and steam employing: - a gas turbine (1) producing energy (3) and combustion gases (4), and - a heat recovery unit (5) supplied with water (6) and employing the heating of said water (6) by recovering heat from the combustion gases (4) of the gas turbine, - a steam production unit (B) employing the heating of water (12) by combustion of a fuel (11) and air (10), and in which the air (10) of the steam production unit (B) is preheated at least in part by heat exchange with the water (6) which supplies the heat recovery unit (5) of the cogeneration unit (A).