WO2017204773A2

WO2017204773A2 - Free electrical energy generation in mdf, osb, chipboard and plywood production facilities with cogeneration - w method

Info

Publication number: WO2017204773A2
Application number: PCT/TR2017/050249
Authority: WO
Inventors: Yusuf POLAT; Ahmet DALGIN; Harun POLAT
Original assignee: Polkar Orman Urunleri Ve Enerji A S
Current assignee: Polkar Orman Urunleri Ve Enerji A S
Priority date: 2016-05-27
Filing date: 2017-06-06
Publication date: 2017-11-30
Anticipated expiration: 2018-11-27
Also published as: WO2017204773A3; PH12018501927A1; WO2017204773A4; WO2017204773A8

Abstract

The basic condition of thermodynamics is that it is closed circuit. This is a main prerequisite for a thermodynamics system to be measurable and controllable. This is in full the ground on which CHP-w has been set up. There should not be any misconception about CHP-w like that; how can a thermodynamic equality produce more work reversely ? It is a fact that an equality must be the same on both sides. However, Cogeneration and Cogeneration-w are not two sides of an equality. Cogeneration and Cogeneration- w consist of a seperate equations in itself. Cogeneration is a method of recovering of the heat by using thermodynamic parameters that has fallen into an inert state in an open system. Whereas, the CHP-w predicates on a closed thermodynamic system which aspires to arise the work output as target. CHP-w method has been set up over the features of taking under control to boiler inner combustion- fluid balance with elastic superheated steam production level, except for flue gas avoiding to directly use of boiler inner heat as much as possible, collecting to boiler inner heat in a only hand by producing superheated steam and having been able to converted the enthalpy/ heat temperature and kinetic energy/ pressure into one another through different steam types in a closed system. CHP-w energy generation method obtains as much superheated steam as possible from the boiler inner heat, excluding to the flue gas and produces the work from it. If the steam to be remained in desired type and amount from the work generation by taking from turbine output whether directly as steam, or which uses by converting it over again to the heat energy is the name of a closed thermodynamic system. Provided that to use CHP-w method, the MDF wood panel production facilities in particular have the opportunity to generate electrical energy at a highly significant rate with their own biomass production residues. The same thing is a valid state for other wood-based panel manufacturing facilities whose woody-biomass residues to be left from production is not as much as MDF production process. The rate of heat required to produce superheated steam is very low. All the work done by the superheated steam is only done with this small amount of energy. At the same time this is the total amount of energy that is lost by transforming to work in a closed system. It is the cost of work. The most largest part of the generated heat in the boiler is spent to the water at 104°C temperature to convert to saturated steam. However, this spent-heat energy can be recovered again through a suitable type of steam in a closed system and can be evaluated in the manner what is desired, whereever it is needed.

Description

DESCRIPTION

FREE ELECTRICAL ENERGY GENERATION IN M DF, OSB, CHIPBOARD AND PLYWOOD PRODUCTION FACILITIES WITH COGENERATION -W METHOD

The invention, cogeneration-w ( CHP-w) energy production method and what was developed for its becoming functional of steam and heat energy operation systems (7),(9) with closed-semi closed circuts, is that of being adapted to MDF,OSB, chipboard and plywood production (14) processes.

Thus, while heat and steam that is requirement of production line (14) delivers to, a significant proportion of the electrical energy (11) required by the plant will be simultaneously achieved free of charge without using any additional fuel. Steam, heat and hot oil (4) are needed to produce M DF/ HDF (medium / high density fiberboard), OSB (oriented strand board), plywood and particle board (14) The quantities of these needs are determined by the production capacities of the installed facilities (14)

Generally, solid fuel boilers are used to obtain heat, steam (18) and hot oil (4) in the existing

M DF/HDF, OSB, Chipboard and Plywood panel production facilities (14) Steam (18) is obtained from hot oil (4) In the same way, hot oil (4) is used for dring (3) and press plate heating as well. In solid fuel boilers (26),

• Wood and wood residues,

• Saw and sanding waste,

• Coal,

· Fuel oil, natural gas (according to boiler type),

• Etc.

The heat obtained by burning is used in in production processes (14) A significant portion of the heat and steam (18) energy is discharged through the chimney (29) The reason for this is that one end of these systems were designed to work to suitable to open circuit way (7,29), (18,29) The MDF, OSB, Chipboard and plywood panel plant facilities (14) that have been designed according to traditional energy production and operation systems obtain to the steam (18), (19) required for their production from low pressure steam boilers which produces saturated steam.

Since the traditional energy solutions used by the wood-based panel manufacturing facilities (14) do not make direct use of the flue gas (7) heat, as mentioned above they provide the heat required for the dryer (3) from the hot oil (4) using entalphy method. This also raises the need so much more for hot oil (4) and the installed boiler (26) capacity of the facility (14) unnecessarily over normal level.

M DF/ HDF, OSB, Chipboard and plywood panel production facilities (14) will be hereinafter referred to as "wood-based panel production facilities" Similarly, the word work will also be used to cover the meaning of electricity. According to the first law of thermodynamics, energy conservation is absolute. Accordingly, between any two interactive system the heat and work transforming are proportional to each other.

Otherwise, the amount of ingoing and outgoing energy to the system must be equal to each other. The phenomenon that causes this is that energy-bearing particles and electrons that make up the atom make an effort to return to their own energy levels.

The energy generation method CHP-w is in accordance with the first law of thermodynamics. In fact, it formulizes to its own internal running of the mechanism providing that to be established the proportional relationship between heat and extra work/ electricity within this frame of mathematical equation. It do does this, too on the basis of the following question; how should I establish the thermodynamics relationship between the total generated heat energy and the work/ electricity in closed circuit system so that I can obtain the maksimum work output? Because there is a direct proportional relationship between heat and the work this is a question that must be answered based on thermodynamics. At first sight the answer can be given either as an increase in the initial heat energy or as being used of the heat energy in the boiler in the work generation. However these responses may only corresponds to against accepting that the fuel input quantity increasing or ignoring that the energy requirement of the production line. Whereas CHP-w is the solution of suppling heat and steam energy demanded by the production line and at the same time generating more electricity than Cogeneration with the same amount of fuel.

In that case how can be the work output inreased without giving additional heat to the system? By using the same amount of fuel extra work/ electricity generation by CHP-w method develops of the energy of being held/ trapped as heat in the boiler, having been able to converted the enthalpy/ heat, temperature and kinetic energy/ pressure into one another through different steam types in a closed system, being operated in closed-semi closed circuts, first in generation of electricity and then in suppling steam and heat (by steam enthalpy) requirement of production facilities, depending on progressive usage and to be rendered functional.

When the natural relationship between steam, pressure, temperature and entalphy/ heat is examined, it is seen that there is an important dependence amongst these, which needs to be carefully considered. The necessary heat energy amount for producing of superheated steam being used in doing work stays to quite small beside of heat energy that is spent in the course of converting it to saturated steam. Most of the energy used in the production of superheated steam is consumed during the transfer of entire boiling water to steam/ gas phase which is pumped to the boiler at 104°C temperature. On the other hand in order to increase the temperature of the dry steam in quite low amount of heat energy is required. Compared to consumed heat, the dry steam atoms, to which temperature rise excessively rapid rate, store this temperature to their bodies in the form of kinetic energy. This kinetic energy also makes up the occurence reason of their pressure application capabilities what is their potential of producing work at the same time. When we obversely make the same explanation, the process operates as follows; the superheated steam atoms that lose heat quickly, if the steam in hand is low in pressure, relatively higher in entalphy.

As to above involved explanations what is the existent dependence between steam, pressure, temperature and heat, we can sum up under these titles;

• According to steam, superheated steam' entalphy is relatively low, if the temperature and pressure are so much higher. This alteration between temperature and entalphy is due to the fact that its temperature has been increased by a less heat energy. And therefore, its entalphy is relatively low. • According to superheated steam, steams' entalphy is relatively high, if the pressure and temperature are so much lower. The high entalphy is due to the high heat energy that vapor has absorbed during the transition from molecular phase to atomic phase.

• On the steam basis low pressure means heat, if high temperature do means kinetic energy.

For this reason when the superheated steam is used to produce work and the saturated steam is used to take advantage of its entalphy, they are getting evaulated of much more efficient level.

CHP-w does not aim to reduce fuel costs by converting the increase in efficiency to energy saving, since a probable shrinkage in the amount of total calorie-generated heat energy leads to work loss. Therefore, it aspires to preserve the magnitude of the current system. On top of that, preferably on condition that arising the boiler size (26), owing to knowing of much more rising of total energy efficiency in proportional basis, it voluntarily gives support to increasing of boiler capacity. Moreover, the general concept that is formed on is very suitable to produce a solution intended to capacity increasing. It collects to the total heat in a single hand and uses it to create additional work/ capacity. Having been collected in a only hand which is available heat, except for the heat necessarily to be discharged by flue gas means as soon as the direct heat possible for not being taken out of the boiler, being used of all heat "by saving" in the boiler with the aim of producing superheated steam. CHP-w defines this as heat energy trapping in the boiler. If a significant part of heat energy of which the production line requires is obtained from steam with low pressure-relatively high entalphy through heat transfer "steam exchanger" procedure. CHP-w refers to this method with the same terms as "gradual and circular usage" that it uses for the flue gas circulation. What is needed to steam of production line is provided with turbine outlet (16) as saturated or dry steam (18,19) according to its characteristics. The process of directing the steam (18,19) that changes its type at the turbine to the production line (14) is called as "alternating usage of steam "by CHP-w To use through production processes steam (18,19) and heat energy dependent wood panel manufacturing facilities (14)have never directed to electricity generation (11) on the basis of its own wood-based residues until today. They produce electrical energy with a system where the heat energy attains to in a seperate boiler system from natural gas which is a second kind fuel. However, the alternating, gradual and circular use of flue gas (7), heat and steam (18,19) energy in closed-semi closed circuit metal pipes will bring about to be operated in most effective way of the generated energy, too, as well as elimating energy loses. High energy efficiency to be reached through energy operation systems that renders possible to be functional of CHP-w will present simultaneously oppourtunity to production facility to be able to supply to both heat and steam (18,19) energy demand and significant portion of electrical energy (11) requirement by CHP-w energy generation method, which was to consume under the known conditions with the same amount of fuel level in a only boiler system.

To the above description by main outlines, in line with the basic principle definition of CHP-w method, we do can reversely as follows; from the energy produced "trapped" in the superheated steam boiler (26) in the first place electrical energy generation (11) as much setting as the rate between boiler inner combustion and fluid balance, as for that the heat and steam energy which is intended being remained from it (from electricity generation) where being conditioned to use in wood-based board production processes (4,3,5,18,19) in closed-semi closed circuit energy operation systems (7),(9) which is in features as alternating gradually. Gaining functionally qualification of CHP-w and how it opens out the door going to the way to free electricity (11) generation in a wood-based panel production facility (14) will be clarified more in the following detailed processes to trace.

• The superheated steam boiler (26) is installed to wood-based panel production facility (14) in order to generate energy.

• Our flue gas energy operating system (7) uses in gradual and circular flue gas necessarily to be discharged in obtaining hot oil (4), in making dring process and/ or feeding to secondary air line.

• For being evaluated of generated heat energy in the best way it is avoided to directly use of boiler inner heat as much as possible. As much as for being able to collected to boiler inner heat possible in a only hand, the steam (9) production is on target aimed thereof. In boiler systems (26) the pumped water to the boiler at 104°C and the produced steam from it is also utilized to establish the boiler inner combustion and fluid balance at the same time.

• The superheated steam (9) required to generate electricity (11) after performing its function through diverse and alternating successive stages in the closed circuit will also be used with the aim of suppling to the steam (18),(19) needed by wood-based panel production facility (14) After transferring a significant part of its kinetic energy to the rotor propellers as rotary motion in the turbine (10) inlet, the superheated steam (9) subjected to pressure and temperature decrease will be taken from the turbine outlet (16) by the reduction method in desired quantity and pressure level and will be transferred to wood-based panel production facility (14) The steam (18,19) supplied to the system from the turbine outlet (16) for being used in wood-based panel producing (14) is the same steam (18),(19) that is used for electrical energy generation (11) in the turbine (10) previously. This steam (9) first in generating electrical energy (11) and then alternately in meeting the needs (18,19) of the wood-based panel manufacturing facility is used for different purposes.

• Our heat-steam energy operation system (9), which is to the entalphy/ heat to obtain from the steam where it is in its hand in high quantities, has potentially ability to use in the way of supporting or substitution to flue gas (7) and boiler inner heat that is being used for the hot boiler (4) and/ or dring unit (3) It is in the situation to be able to do this with the steam to take from turbine outlet (16), which is exposed to due to pressure and temperature drop and hence, no more being favorite in electricity (11) generation.

In the context of this invention, electrical energy (11) and in particular MDF wood-based panel production (14) are to become integral parts of a production relationship that mutually supports each other. Due to the quantity of wood residue to induce, there is no obstacle in front of a wood- based panel production facility (14) of being able to produced to all the total energy (4,3,5),(18,19) required during production processes, as for the electricity (11) that the substantial part of it, with solely own biomass residues.

In case the wood based panel production facilities (14), instead of burning directly to their own biomass residues in the boiler (26), which is suitable to be pellet, directs to manufacture pellet that the calorific burning value as per unite weight is much higher, electrical energy (11) generation capacity is going to ascend to upper levels. When the invention is evaluated in another aspect it comprises to uncover to energy generation potential (11) in inert state in the existing facilities (14) by activating energy generation and operation (7),(9), in which the energy is produced and operated by the out date current tecnologies and therefore causing to serious source loss. For having been run in features closed and semi-closed circuit energy operation system, all heat energy of the flue gas (7) is absorbed whereby air pollution dependent to high carbon emission which originates fom being released directly to the atmosphere is also prevented, as it is usual in the conventional structures. Alternating and circular energy operation system that we have developed precludes discharging of flue gas (7) to the air (29) The steam that remains from turbine outlet (20), steam exchanger (19) and usage of wood-based panel production facility (18) will convert to exhaust steam. This fluid in semi-condenced state following the pre-cooling transaction (21), with the help of feeding-fresh water (22) to be added at ambient temperature exposing to full condensation will be transported to the water tank (24) And then this water, which has reached to the temperature of 104°C through steam exchanger (19) in the water tank (24) will be transferred back to the boiler (26) and converted again for being used over again in the production of superheated steam (9) Within the systematic integrity, this phase transformation (20),(21),(22),(23),(24),(25),(26) will continue in a continous cycle.

Figure 1/1 shows the general boiler flow diagram. In other words, it is a simple model of the energy operation systems (7),(9) developed for becoming of functional of CHP-w energy generation method with closed thermodynamics system. It consists of a single page.

Explanations of figures that are shown on the boiler schema ;

1. Proportional valve 1: This valve will provide discharging of flue gas from chimney (29) by closing itself automatically when any compression in the seconder airline (5) occurs while it back- pumped into boiler. Another closed valve (30) in the chimney will be opened automatically to discharge the gas. This valve controlled by computer aided automation has the ability to arrange the amount of flue gas (7) that is suitable for the efficiency of combustion cell.

2. Proportional valve 2: When a compression in the flue gas line occurs that is transferred to dryer (3), this valve/mechanism is closed automatically to discharge gas from the chimney (29). Another closed valve located in chimney (30) is used for discharging while its being opened automatically. Also, thanks to this valve, the amount of flue gas (7) that should be steered to dryer is controlled using computer aided automation control system.

3. Dryer/ dring unit: If heat is needed, the desired quantity and rate of flue gas is transferred from boiler through ventilator with automation control (27) and it is sent to production line (14) for dring.

4. Superheated/ hot oil boiler: it is a boiler system where the oil is heated, which is needed by the wood panel production facility (14) Seconder hot air line: After most energy of the flue gas (7) circulated in closed and semi - closed circuit (4-3-5) is taken off and after filtration, it is re-pumped into boiler (26) under control to heat the air that is responsible for burning and to arrange the combustion balance. Flue gas output valve 1: This valve is used automatically for immediate discharge of flue gas (7) that steered to hot oil coils (4) and from it to multi-cyclone (28) line if any counter pressure possibility on the flue gas route (7) exists. This valve has the eligibility to be controlled and directed by computer-aided automation control system. Output point of flue gas from boiler and its route in closed and semi-closed to trace: For heating of coils in the hot oil boiler (4) where oil reaches to a temperature at 280°C and then feeding to dryer (3) and seconder hot air line (5) to be absorbed of the flue gas in control by ventilator (27) is the route from the boiler (26) output to follow which is in features closed and semi closed circuits. Both the flue gas and its route to follow has been given the same reference number in the description set. Resulting from manner of taking out flue gas from the boiler, with being directed to hot oil boiler (4), dring unit (3) and seconder air line (5) in control, which occur to the usage type we give to "flue gas energy operation system" name. Likewise, we codify this, too with 7 figure. Output point of superheated steam from boiler: the output point where superheated steam is taken from boiler (26) to take advantage of itself in an area for any purpose. However, wood-based panel production facilities has no need for such a steam to be taken from number 8. This is used for another adaptations of CHP-w. The steam input point into turbine: After transferring its energy to the turbine in a closed thermodynamic system by tranferring to be come to a state of different steam types of superheated steam where enters into turbine. And then, what is to be directed to wood- based panel process (18) and steam exchanger (19) in features closed and semi closed circuits of saturated steam is proceed with usage in different ways until becoming to condenced steam. In the description set, both superheated steam and its turbine inlet point is numbered with 9 figure. By getting together in the boiler of heat and water at 104°C along with steam forming, with insisting of heat a little bit more transforming to superheated steam, with this enthusiasm doing work together and then both sides again by going to its own way, to the consuming process to its own virtue by living in the area where it is required we give closed circuit "heat-steam energy operation system" to name. Likewise, such superheated steam and turbine steam inlet point as we numerize this, too with 9 figure. Turbine: It is an equipment where electric energy (11) is generated through rotating of generator. Generator: It is winding assembly where where electric energy is generated through the rotation of steam turbine (10) Transformer: It regulates desired voltage and current values in the certain power of electrical energy (11) which is generated by electric generator. 13. Medium voltage switchgear group: This is substation or main distribution switchgear group where electric voltage is converted from high form into low form or vice versa that is coming from transformers.

14. Production facility (plant): This is the industrial plant where both heat and steam (18,19) is needed.

15. Interconnected system: The system where variation arrangement is provided at the level of electricity generation and consumption.

16. Turbine steam output point: Steam output point from turbine where desired steam exists for utilizing in steam heat exchanger or in the production process (14) 17. Steam collector: This is the distribution mechanism where the steam is taken off from

turbine output (16) ( back pressure & condensing extraction) and transferred to production line (18) and to the steam exchanger (19) considering desired steam quantity.

18. The output point of steam: The point where steam exists and is steered to production line.

The steam that is taken off through reduction method from turbine output (16) is steered through collector (17) to the production line (14) in order to meet its demand.

19. Steam exchanger: The steam exchanger where the temperature of whole water is increased to 104°C in water boiler (24) This steam completed its task through exchanger is included into system for recovery via the point marked 21 on the boiler schema.

20. Turbine exhaust output: The superheated steam (9) that discharges its whole energy into turbine by the type of steam turbine from exhaust ouput (20) will exist as hot water with lower pressure having half a phase change. Half condensed this water (21), as shown below, is handled as full complete condensation (21,22) and then after increasing its temperature to

104°C it will be converted into superheated steam for reusing.

21. Surface cooling (cell condensation): This is the section (place)where surface cooling process is done.

22. Phase change (cell condensation 2): This is the section (place) where full phase change is occuring with addition of fresh water.

23. Pump cell 1: This is the first pump which is used for pumping water to water boiler (24) that is totally in liquid phase.

24. Water boiler: This is the water boiler where the whole water is reserved and where its

temperature is increased to 104°C by steam exchanger (19) Pump cell 2: This is the second pump that is used for pumping the boiled water in water boiler (24) whose temperature has been reached till 104°C into superheated steam boiler (26) Superheated steam boiler: This is the production center of heat energy where superheated steam with high pressure is generated. Until now, wood-based production facilities (14) have never utilized to this unit in their industrial production line (14) and just for electric energy generation organizations have used it only for production of electric energy. Ventilator: This is the air intake system that provides with absorbtion to desired amount of flue gas (7) from the boiler (26) under control. Multi-cyclone: This is a mechanic assembly where flue gas (7) is filtered. Chimney: This is the discharge point that provides immediate discharging of flue gas (7) if any compression is occured in dryer (3) or in seconder air line (5) Flue gas output valve 2: This valve is placed into chimney (29) that is closed in normal circumstances. In emergency states this valve is operated automatically.

Claims

1. The invention, what is a developed energy operation system which gives to energy generation functionality to Cogeneration-w energy production method is that being used in MDF, OSB, Chipboard ve Plywood production process (14) , its feature ;

- being combined to superheated steam boiler (26) with automation control system,

- holding heat in the superheated steam boiler (26),

- the absorption of the flue gas (7) from boiler through ventilator (27) and valves (1),(2) with automation control,

- putting automatic gas discharge valves (6),(30) on the output of boiler (6) and output of the chimney (30) that are sensible to the pressure in order for discharging of flue gas (7) securely,

- using the flue gas (7) for producing superheated oil (4) , making drying (3) and as seconder air (5) in the boiler (26),

- steering steam into production (18) and isteam exchanger (19) that is taken off from turbine output (16) by the type of turbines,

- what is exposed to the condensation of the steam (20), following being transferred to the full liquid phase (21),(22) that to be reached to 104 °C temperature (24), being converted to produce superheated steam (9) for reuse,

is that consisting of the process steps above.

2. The invention, it is the 1^st process step in the demand 1, its feature; that using to the production potential of high capacity of superheated steam (9) and flue gas heat (7) that superheated steam boiler (26) has.

3. The invention, it is the 2^nd process step in the demand 1, its feature; that obtaining to heat energy required in hot oil boiler (4) and dring unit (3) instead of taking direct from the boiler (26), as much amount as from flue gas (7) as necessarily to be discharged, if the rest from steam with low pressure- relatively high entalphy (18) to take by the type of from turbine output (16)with heat transferring procedure as gradual and circular.

4. The invention, it is the 2, 3 and 5^th process steps in the demand 1, its feature; that using the flue gas heat (7) in obtaining superheated oil (4), in making the drying process (3) and in feeding secondary hot air line (5),which is absorbed from the boiler (26) in desired quantity, which is in these features as cycled gradually in closed-semi-closed circuits (4),(3),(5)

5. The invention, it is the 6^th process step in the demand 1, its feature; that using the steam needed (18),(19) by wood-based panel production facility (14) by providing with reduction method from the turbine output (16) by the type of turbine, which is alternately in closed and semi-closed (9),(18),(19),(20),(21) circuit systems.

6. The invention, it is the discovering of free electric energy genereation in wood-based panel production facility by using Cogeneration-w method , its feature; that pumping the desired quantity (25) of boiled water (24) whose temperature is 104 °C into superheated steam boiler (26) and converting it into superheated steam as much setting as the rate between boiler inner combustion and fluid balance (7)

7. The invention, according to claim 3 it is the using of heat energy being produced in the boiler (26), which is in gradual and circular, its feature; using that having been able to converted of enthalpy/ heat temperature and kinetic energy/ pressure into one another through different steam types in a closed system.