Improving power efficiency why not now?

Improving power efficiency—why not now?

Energy Efficiency: Improving Power Efficiency

Improving Power Efficiency—Why Not Now?

Oxistop LLC

Youngstown State University

Sustainable Energy Forum

June 8, 2010

welcome and thank you

Defining the opportunity

Introduction of the existing technologies

Benefits of the existing technologies

Recognizing obstacles

Overcoming obstacles

presentation objectives

Current economic realities have forced

the Power Utility Industry and America's Heavy Industries

to use what was considered by them to be discretionary

dollars as a means of maintaining basic operations,

leaving little money or incentive for investing in new

technologies for efficient power generation development.

energy efficiency and conservation

Economic Realities

―It's hard to remember now.

But before Congress got all bogged

down with healthcare reform

last summer, the House had passed a

major piece of energy and climate

legislation that would have capped

greenhouse gas emissions and put

billions into renewable energy and new

technologies...‖

K.G. U.S. News & World Report, Summer 2010

Improving power efficiency—why not now?

Technologies exist today that are proven solutions

in other industries for problems associated with energy

efficiency and energy conservation issues and have

existed for many years.


Ceramic Coatings And

Magnetic Field Technologies

• No real economic incentive to change

current practices

• New to the Power Utility Industry, where

they are considered experimental

• Not fully validated and tested by the Power

Utility Industry


Why Are The Technologies Not Being Used

In The Power Utility Industry?

• High emissivity Ceramic coatings for energy

enhancement

• Low emissivity Ceramic coatings for energy

conservation

• Magnetic Field Units (MFU), conservation of

finite natural resources for fuel and water

treatment technologies


Ceramic Coatings And Magnetic Fields

What Are Some Of These Technologies?

high emissivity ceramic coatings

improving fuel efficiencies in various

industries

reducing slag and residue buildup

resisting corrosion and erosion

preventing oxidation of boiler tubes

Ceramic boiler tube coatings improve

power generation and reliability of the boiler

while reducing emissions.

ALL CRITICAL TO EFFICIENCY AND AVAILABILITY OF POWER GENERATION EQUIPMENT

Base metal

Procera™ Coating

Slag buildup creates many problems, including

loss in boiler efficiency, potentially damage to the

unit and danger to personnel from falling slag.

slag challenges & coating solutions

Slag buildup on

uncoated tube wall

Slag that has shed

off the ceramic coated

tube wall

Magnification of ceramic

coating bond with carbon

steel substrate

Oak Ridge National Laboratory U. S. Department of Energy

corrosion challenges & coating solutions

furnace gas (pyrite)tube metaloxide

slag

sulfide corrosion

sulfides

Challenges: Oxidizing High Sulfur Conditions

Solution: Ceramic Coatings—Protective Layer

tube

metal Ceramic Coating

slag furnace gas (pyrite)

Pro

cera

™ M

C19

-GR

P—

Pro

tecti

ve L

ayer

Ceramic Coating

provide a ―protective

layer,‖ through

complete chemical

and mechanical

bonding to the

tube’s surface

corrosion challenges & coating solutions

AEP ceramic coating case study

(how does this work)

American Electric Power

Picway Power Plant

(2004-2005)


Before coating install,

burner with upper

eyebrow

Trial burner grit blast

surface preparation

Trial burners with ceramic

coating applied

First Installation.

Trial area around burners to stop slag buildup


Technology is verified in the field

Before coating install,

uncoated with eyebrow

Coated burner wall, note

excellent flame profile

Slag shedding off burner

wall coated with

ceramic coating

NRG ceramic coating case study

Huntley’s

expectations

of the coatings

NRG Energy Inc

Huntley Power Plant

(2006-2007)

coating will lessen

the thermal shock and

damage to tubing

overall heat

absorption in the

furnace will improve

cost of application is

below that of other

corrosion coating

options

•

•

•

NRG ceramic coating case study

payback for the cost…24 DAYS

lower furnace exit gas

temperatures (FEGT) as a

result of greater absorption

lower fuel (coal) usage

eliminating over firing to make

steaming rate

maximum megawatt output is

increased to full load of 198

Megawatts, with slightly less

coal burned

•

•

•

Results

Associated Electric

Cooperative Inc

New Madrid Power Plant

(April, 2008)

AECI ceramic coating case study

ash fowling before coatings

NEW MADRID POWER

PLANT CHALLENGES:

• ash fowling control

of inlet and outlets

of secondary

superheater (SSH)

• slag bridging

across front of SSH

• improving fuel

efficiencies and

heat absorption by

reducing slag

Uncoated next to coated,

after 6 months online, un-cleaned

New Madrid’s coating observations

no bridging across

front of SSH

SSH fouling rate

approximately half

of historic rate

coating visible In

some areas and

overall condition

appears very good

higher heat

absorption rate

Economizer Outlet Flue Gas Temperature

•

•

•

•U1 Current Run (Oxistop, 2008)

U1 Summer, 2007 (Control)

U1 Average Summer, 2004 – Winter, 2006–

2007

1. Boiler Bank

2. Superheater

3. Combustion Chamber

4. Hot Cyclone Collector

5. Economizer

6. Air Heater

7. Dust Collector

8. ID Fan

coating application areas(a comprehensive approach)

High emissivity coatings for energy enhancement (Production Side)

Low emissivity coatings for energy conservation (Conservation Side)

low emissivity ceramic coatings

excellent thermal insulation at low

thicknesses

eliminates Corrosion Under Insulation (CUI)

easy application to irregular surfaces

excellent personnel protection

Ceramic thermal insulating coatings for

energy conservation that reduce energy cost and

provide emission control.

conventional insulation

low emissivity ceramic coatings

What is the difference between conventional

insulation and Thermal Insulation Coatings (TIC).

CUI

Difficult Repairs

Maintenance

Wear/Vibration

No Inspect Ability

Limited Protection

conventional insulation thermal insulation coatings

No More CUI

Easy Repairs/Touch Ups

No Regular Maintenance

Virtually No Wear

Total Inspect Ability

Constant Substrate Protection

Job was expedited by Hurricanes Katrina & Rita

thermal insulation coating (TIC)

ceramic coating case study I

Diffuser

Substrate: Diffuser (sugar mill)

Problem: CUI, Personnel Protection,

Heat Retention

Reason: Needed to keep diffuser at

steady temp and protect

personnel from burns

Starting Temp = 190°F (87°C)

Post app. Temp = 110°F (43°C)

DFT = 60 mils

Sugar mill diffuser was not cost

effective to conventionally insulate

Coating was selected due to its rapid

application as well as total service

ability

Post application all of its sugar mill

process was well within the design

parameters and allowed the facility to

save tremendous dollars on energy

•

•

•

Shell Heat Exchanger

Substrate: Shell Heat Exchanger

Problem: CUI, Personnel Protection,

Reason: Ease of maintenance,

personnel protection

Starting Temp = 200°F (93°C)

Post app. Temp = 110°F (43°C)

DFT = 40-60 mils (1.0-1.5mm)

Unit had a process temperature

requirements starting at 200F and

tapering to 100 F. The coating allowed

the facility to save costs of total

insulation as the application could be

tailor-sprayed to temperature

requirements.

Use of DTI brought the goal of

Personnel Protection well with their

limits and eliminated CUI.

•

•

thermal insulation coating (TIC)

ceramic coating case study II

coatings for energy conservation

(commercial applications)

How Do The Coatings Work?

water treatment

No energy required to operate

Has no parts subject to wear and no

moving parts (No maintenance)

Greatly reducing of chemical expenses associated with water

treatment

Magnet system is a permanent solution to water treatment

issues, giving immediate benefit

Life and effectiveness of the system with match the operating

equipment

Magnetic Field Units (MFU), conservation of

finite natural resources for fuel and water

treatment technologies.

water treatment

Cooling Water Systems

and Boiler Efficiencies

Magnetic Field Units for water replace the cost of

chemicals and maintenance cleanings by applying a

safe, permanent, cathodic protection voltage to

cooling process liquids.

The MFU aggressively removes hard scale,

deposits, and bio-fouling that can reduce or eliminate

waterside related maintenance outages.

water treatment

Cooling Water Systems

and Boiler Efficiencies

Cooling towers and condensers can create a back

pressure within the turbine if the system’s efficiency

is compromised by calcium carbonate build up and

organic matter accumulation.

The traditional way to treat this occurrence is to treat

the system with chemicals to deal with the various

issues—a costly balancing act never 100%

effective, and scheduled cleanings are required and

a certain amount of back-pressure is tolerated.

Birchwood 9% Case Study

9% Increase In Power Output Reported

With HYDROLATOR™

• 9% increase, to reach designed capacity (output

reached 256 MW)

• 20 MW additional production (Historically, this

plant's peak output never exceeded 236 MW)

• No condenser cleaning was required after

increased power output and installation—

$300,000/yr savings in chemical treatment

expenses

• $7 million/yr profit as a result of increased power

output and HYDROLATOR’s permanent cleaning

• HYDROLATOR equipment has been utilized since

2000 with consistent performance results

fuel conservation

MFU for conservation

for fuel: MAXSYS FUEL

SYSTEMS

In-line magnetic fuel treatment system (minimum 5% fuel savings assured)

Pre-treat gas and oil prior to combustion to enhance combustion efficiency

while lowering emissions

Retrofit system - no power or maintenance required

No interference to the process and combustion plant

Does not affect burning equipment warranty

Compatible with all burners across a range of industries

pushing and pulling

strategies effect energy flow

WHAT DOES THIS MEAN…

Can Power Efficiency

Be Improved Today?

YES IT CAN!BY ―PUSHING‖ WITH CERAMIC COATINGS AND

―PULLING‖ WITH MAGNETIC FIELD TECHNOLOGIES

TO CREATE NEW ENERGY FLOW DYNAMICS

pushing and pulling energy flow

Push And Pull Strategies For More Efficient Power

Generation And Increased Revenue Income

recognizing obstacles

Inherent problems are that vested interest

groups are against new technologies for energy

efficiency and conservation because:

• the ―why fix what is not broke‖

• owners and operators are ―set in their ways‖ (stay the course) or feel

that their job security is at risk.

• in many cases, fuel costs are passed-on to the end consumer.

• boiler manufacturers’ answer is to ―simply build a bigger box

[boiler].‖

• owners have vested interests in traditional technologies; such as

chemicals; different boiler and burner designs; or other tube coating

technologies such as weld overlay and thermal (metal) spray.

overcoming obstacles

Additional Funding (Grants)

And Real Incentives For:

$ For Funding – RESEARCH AND VALIDATION, such as education

institutions and testing and research facilities such as

Babcock & Wilcox Company Research Center (BWRC)

in Barberton, Ohio.

$ For Funding – FIELD TRIALS with ―End Users‖—Heavy Industry and

Power Generation (Companies that would benefit by

use of these Technologies)

$ To Provide Funding – For companies that specialize in promoting new

technologies that are dedicated to energy efficiency

and conservation.

Tim Batton, President

Oxistop LLC • Salem Energy Solutions • Sáetech LLC

Phone: 330-332-1111 • Cell: 330-885-0902

1413 Quaker Circle, Salem Industrial Park • Salem, Ohio 44460 • www.oxistopllc.com

Improving power efficiency—

why not now!

Today’s use of these technologies can be the

bridge to our future evolution in efficient production

and conversation of our energy resources.

Improving power efficiency why not now?

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