Industrial enterprises are still dependent on energy supply problems. Among them, there is a restriction of capacity from local power networks, overestimated tariffs, inconsistency of quality and reliability of power supply. All together, this leads to unacceptable operational costs and the loss of competitiveness.

ENERGY AUTONOMY IS THE BASIS OF COMPETITIVENESS

Computable and far-sighted industrialists, especially in energy-intensive industries, increasingly achieve the competitiveness of their enterprises through the creation of a plant's auxiliaries power supply complexes based on GTPP, GRPP, GTU-TPP or CCGT-TPP.

The use of cogeneration, combined cycle gas or tri-generation technologies ensures the production needs of enterprises with the necessary amounts of electricity, hot water, steam and cold.

The creation of autonomous power supply complexes allows achieving a number of goals, among which:

• guaranteed coverage of electrical loads under conditions of network restrictions;
• generation of own thermal power for various facilities of the enterprise;
• ensuring the production process needs in hot water, steam and cold;
• significant reduction of energy consumption costs;
• reduction of the company's dependence on the tariff policy in the electricity market.

The investment attractiveness and financial efficiency of such power supply complexes is also due to the economical expenditure and full control by the consumer owner.

ADVANTAGES OF AUTONOMOUS POWER SUPPLY COMPLEXES

As a result, the essential merits of autonomous power supply complexes are:

• high technological and economic efficiency (efficiency over 90% in cogeneration and tri-generation modes);
• low cost of generated electricity and heat (two and more times lower than network tariffs – due to more efficient generation, lack of transport losses and overhead costs);
• short payback period (about 5 years when working in a simple cycle or up to 2-4 years with complete heat recovery – in cogeneration and tri-generation modes);
• minimum commissioning time. 

Thus, autonomous generating capacities allow advanced enterprises to achieve energy efficiency, increase in profitability of production and competitiveness of products.

ENERGAS GROUP IMPLEMENTS

The entire range of fuel gas treatment equipment for autonomous power supply complexes is offered by the ENERGAS Group. First of all, these are block-type gas treatment units (BGTU), booster compressor stations (BCS) and comprehensive gas treatment systems.

Today, only in the oil and gas industry 81 units of ENERGAS provides gas supply to turbines of 24 fields’ power supply complexes.

More 18 units operate as a part of 8 autonomous power supply complexes of industrial enterprises.

At the same time, it guarantees treatment of source gas of almost any quality and composition to the required design parameters for purity, humidity, temperature, pressure and flow rate.

Creators of gas-turbine, gas reciprocating and combined-cycle power units present such reasonable requirements for gas treatment equipment. After all, they are well aware of the dependence of the achievement of design efficiency, the level of reliability and economy of power units on the quality of fuel gas treatment.

Proceeding from this, ENERGAS specialists find the necessary engineering solutions and realize them in the process procedure of comprehensive gas treatment.

GAS TREATMENT PROJECTS – FOR ENTERPRISES’ POWER SUPPLY COMPLEXES

We bring to your attention a number of completed projects on the construction of autonomous power supply complexes and their equipping with process equipment for gas treatment.

Power supply complex of microelectronics plant of JSC Angstrem-T

In Zelenograd, the research and production complex for the production of microelectronics is equipped with its own autonomous gas reciprocating power plant, which operates on a tri-generation cycle and provides the enterprise with the necessary amounts of electricity, heat and cold.

The design electric power of GRPP is 36 MW. The plant is based on five gas reciprocating units (GRU) Wartsila of type 16V34DF with a capacity of 7 MW each. Two-fuel GRUs can operate on gas and diesel fuel.

If necessary, switching between energy carriers occurs automatically, without shutdown and reducing the load. Environmental standards of the power plant comply with all modern standards.

In the GRPP building there is also placed a new boiler house, consisting of four Buderus Logano S825L hot water boilers complete with Saacke combined industrial block burners.

Gas fuel for GRPP and the boiler house is supplied through the multifunctional gas treatment system (GTS) of ENERGAS, which provides the necessary design parameters for purity, temperature, pressure and flow. GTS includes the following process equipment:

• inlet gas filters for pre-treatment of gas;
• gas metering station for fuel consumption measurement;
• separation system (two-stage filters-scrubbers) for fine gas purification;
• compressor station (two gas booster units) for fuel compression;
• in-site gas pipeline. 

The technical specialists of the ENERGAS Group performed turnkey construction and commissioning of the GTS including erection supervision, start-up and adjustment, individual testing and integrated check as part of a power plant.

At the same time engineers of ServicENERGAS LLC conducted training of the customer's personnel for the rules and norms of equipment operation.

Combined cycle power plant of PJSC Mordovcement

The first combined cycle power plant in the history of Russian cement plants was put into operation in 2010.

CCPP supplies large cement production with its own electricity, heating, hot water, and provides drying of raw materials. As early as 2012, with a total electricity consumption of 576 million kW / h, generation from the factory CCPP was 496 million kW / h (86%).

The total capacity of the plant is 102.8 MW (electric capacity – 72 MW, thermal capacity – 30.8 MW). The CCPP power unit is the two gas turbines of type LM2500+G4 DLE produced by General Electric, the steam turbine of type SST-PAC300 (Siemens), the waste heat boiler (HRSG) and the steam boiler of type VITOMAX 200HS (Viessmann).

Here there is operates a booster compressor unit of ENERGAS, designed to treat and supply gas to the turbines at a working pressure of 3.8 MPa. Initially, the BCU had a standby status, but afterwards the unit was switched to the basic operating mode and for today carries the main load for the uninterrupted supply of the power plant with high-quality fuel.

Autonomous power supply complex of Minsk combine of silicate products

The Minsk Combine of Silicate Products (CSP) has been in existence since 1895. At present, it is the largest producer of building and thermal insulation materials in the Republic of Belarus.

Intensive development of production and development of the production of modern products of European quality required the upgrade of the power supply system of the combine. The most profitable option was to equip the enterprise with its own power supply complex with the use of advanced technologies of gas power engineering.

As a result, in 2012, a gas turbine unit (GTU) produced by the Swiss company Turbomach was put into operation on the site of the steam-power workshop of the Minsk CSP. The basis of the GTU brand TBM-C40 is the turbine of type Centaur 40 GS (Solar Turbines Inc.); the capacity of the generating equipment is 3.5 MW.

Fuel gas supply to the GTU turbine is provided by booster compressor unit of Enerproject with a capacity of 1,530 m3 / h, made on the basis of screw oil-filled compressor. The unit is equipped with all necessary engineering systems; its capabilities allow compressing gas from 0.3 to 2.5 MPa.

The entire cycle of pre-start operations on gas supply equipment was performed by the leading technical specialists of the ENERGAS Group – the official representative and partner of the Swiss company Enerproject SA in Russia and CIS countries.

The implementation of the project made it possible to derive a double benefit. Firstly, due to reduction of expenses for the fuel and energy component, the cost of manufactured products decreased, which increased the competitiveness of the combine. Secondly, the power supply complex not only completely supplies electricity to the CSP's own needs, but also allows the company to receive additional profit by selling surplus electricity to local power grids.

Gas turbine power plant of JSC Apatit

In the Vologda region at the site of JSC Apatit (formerly JSC PhosAgro-Cherepovets), the carbamide production complex is integrated with the gas turbine power plant. This is the first production of carbamide full technological cycle, created in the modern history of the country.

Possibilities of own GTPP allowed to reduce specific energy consumption by 2.5 times per 1 ton of products. According to the energy costs (heat and electricity), the new production is 12% more efficient than the existing Russian enterprises. The energy technologies used here provided the enterprise with a qualitatively new level of environmental safety, resource saving, labor productivity and competitiveness.

Captive GTPP is based on the gas turbine unit GE Energy of type LM2500+G4 with electric capacity of 32 MW and a steam waste-heat boiler with a 50 MW thermal capacity of Vapor (Finland). As a fuel natural gas is used.

Compressing and supply of fuel gas to the turbine of the power unit under a design pressure of 3.8 MPa is carried out by booster compressor station of ENERGAS. The process flow diagram of BCS also provides for the ensuring of a set gas supply temperature to the GTU.

The capacity of BCS is 10,000 m3 / h. The station is fully automated; the local ACS is integrated into APCS of power supply complex.

Power supply complex of gas chemical complex of Stavrolen

In 2015 in the city of Budennovsk, Stavropol Region, a thermal power plant with a capacity of 135 MW was put into commercial operation on the site of the Stavrolen gas chemical complex (GCC). Budennovsk TPP is built on the basis of a modern combined cycle gas turbine unit.

CCGT has a design electric capacity of 135 MW and a thermal capacity of 40 Gcal / h. It consists of two gas turbine units of type Industrial Trent 60 WLE (Siemens), two PC-93 waste heat boilers, a steam turbine of SST-400 (Siemens).

The power facility fully meets the needs of GCC Stavrolen in electric and thermal energy. Some of the energy resources are directed to other consumers in the region.

Final treatment, compression and supply of fuel gas to the turbines at a pressure of 5.8 MPa are provided by the booster compressor station. BCS consists of three units, two of which operate in a continuous mode, the third – in hot-standby.

The peculiarity of the process procedure is pressure drop of gas at the inlet. To maintain a constant pressure level, compressor units have been upgraded – a reduction unit is built in the block-module of each CU. The design parameters of gas in terms of purity are provided by additional elements of the filtration system – external coalescing filters-separators equipped with automatic condensate drainage system.

The stage-by-stage commissioning of fuel gas BCS was carried out by the ServicENERGAS Company (ENERGAS Group).

The facility for own power generation of the Kastamonu plant 

Since 2014, in the special economic zone of Alabuga (Republic of Tatarstan) there is operating the Kastamonu plant – Europe's largest enterprise for the production of laminate flooring and wood panels MDF / HDF.

Own electric power for production needs is produced by a gas turbine unit with an installed capacity of 25 MW, created on the basis of the gas turbine of type LM2500+G4 (GE).

The factory GTU-TPP includes a waste heat boiler, the heat capacity of which is also used to provide process procedures. Fuel for the power supply complex is natural gas.

For this project, ENERGAS supplied and commissioned gas treatment and gas supply equipment: block-type gas treatment unit, booster compressor unit, reduction unit.

Block-type gas treatment unit performs flow metering and filtration of gas entering the plant's facilities. BGTU is equipped with a gas metering station and a highly efficient separation system. The degree of gas purification from mechanical impurities and droplet moisture (over 10 μm in size) reaches 99.98%.

BGTU is a sound and heat insulated module with maximum integration of equipment on a single frame; operates in automatic mode; equipped with life support systems (heating, ventilation, lighting) and safety systems (fire detection, gas detection, alarm, firefighting).

Compressor unit compresses gas to 3.8 MPa and feeds it to the GTU-TPP turbine. The unit is housed in a separate all-weather shelter; equipped with a two-level capacity control system and an automated control system with data transfer function on the top level of APCS. The gas consumption of CU is 12,000 m3 / h.

The reduction unit is designed to reduce the inlet gas pressure from 1.2 MPa to 0.4 MPa before it is fed to the boiler house of the plant. The unit's capacity is 3,000 m3 / h.

According to the schedule agreed with the customer, the service engineers of ENERGAS perform comprehensive maintenance of equipment.

ENERGY EFFICIENCY OF ENTERPRISES IS ALREADY REALITY

Many enterprise’s heads in practice are convinced of the specific possibilities of autonomous power supply. Enterprises, leaders of the domestic industry, benefit from their own generating capacities and achieve energy efficiency, profitability and competitiveness of their products. Benefits to ensure the production of their own electricity and heat have become obvious to them.

The basis of such achievements is the professional cooperation of designers, manufacturers and suppliers of equipment, builders and power engineers. So, according to special requirements of customers, modern power supply complexes of industrial enterprises are created coordinately, quickly and qualitatively.

Specialized magazine "Industrial and heating boiler rooms and mini-CHPP"