Improving power efficiency—why not now?
welcome and thank you
Energy Efficiency: Improving Power Efficiency
Improving Power Efficiency—Why Not Now?
Oxistop LLC
Youngstown State University
Sustainable Energy Forum
June 8, 2010
presentation objectives

Defining the opportunity

Introduction of the existing technologies

Benefits of the existing technologies

Recognizing obstacles

Overcoming obstacles
energy efficiency and conservation
Economic Realities
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.
Improving power efficiency—why not now?
“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
energy efficiency and conservation
Ceramic Coatings And
Magnetic Field Technologies
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.
energy efficiency and conservation
Why Are The Technologies Not Being Used
In The Power Utility Industry?
•
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
energy efficiency and conservation
Ceramic Coatings And Magnetic Fields
What Are Some Of These Technologies?
•
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
high emissivity ceramic coatings
Ceramic boiler tube coatings improve
power generation and reliability of the boiler
while reducing emissions.

improving fuel efficiencies in various
industries

reducing slag and residue buildup

resisting corrosion and erosion

preventing oxidation of boiler tubes
ALL CRITICAL TO EFFICIENCY AND AVAILABILITY OF POWER GENERATION EQUIPMENT
slag challenges & coating solutions
Slag buildup creates many problems, including
loss in boiler efficiency, potentially damage to the
unit and danger to personnel from falling slag.
Procera™ Coating
Base metal
Oak Ridge National Laboratory U. S. Department of Energy
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
corrosion challenges & coating solutions
Challenges: Oxidizing High Sulfur Conditions
sulfides
tube metal
slag
oxide
sulfide corrosion
furnace gas (pyrite)
corrosion challenges & coating solutions
Ceramic Coating
provide a “protective
layer,” through
complete chemical
and mechanical
bonding to the
tube’s surface
Procera™ MC19-GRP—Protective Layer
Solution: Ceramic Coatings—Protective Layer
tube
metal
slag
Ceramic Coating
furnace gas (pyrite)
AEP ceramic coating case study
(how does this work)
American Electric Power
Picway Power Plant
(2004-2005)
AEP ceramic coating case study
First Installation.
Trial area around burners to stop slag buildup
Before coating install,
burner with upper
eyebrow
Trial burner grit blast
surface preparation
Trial burners with ceramic
coating applied
AEP ceramic coating case study
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
• coating will lessen
the thermal shock and
damage to tubing
• overall heat
absorption in the
furnace will improve
NRG Energy Inc
Huntley Power Plant
(2006-2007)
• cost of application is
below that of other
corrosion coating
options
NRG ceramic coating case study
payback for the cost…24 DAYS
Results
• 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
AECI ceramic coating case study
Associated Electric
Cooperative Inc
New Madrid Power Plant
(April, 2008)
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
Economizer Outlet Flue Gas Temperature
• 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
U1 Current Run (Oxistop, 2008)
• higher heat
absorption rate
U1 Summer, 2007 (Control)
U1 Average Summer, 2004 – Winter, 2006–
2007
coating application areas
(a comprehensive approach)
1.
2.
3.
4.
Boiler Bank
Superheater
Combustion Chamber
Hot Cyclone Collector
5.
6.
7.
8.
Economizer
Air Heater
Dust Collector
ID Fan
High emissivity coatings for energy enhancement (Production Side)
Low emissivity coatings for energy conservation (Conservation Side)
low emissivity ceramic coatings
Ceramic thermal insulating coatings for
energy conservation that reduce energy cost and
provide emission control.

excellent thermal insulation at low
thicknesses

eliminates Corrosion Under Insulation (CUI)

easy application to irregular surfaces

excellent personnel protection
conventional insulation
low emissivity ceramic coatings
What is the difference between conventional
insulation and Thermal Insulation Coatings (TIC).
conventional insulation
thermal insulation coatings

CUI

No More CUI

Difficult Repairs

Easy Repairs/Touch Ups

Maintenance

No Regular Maintenance

Wear/Vibration

Virtually No Wear

No Inspect Ability

Total Inspect Ability

Limited Protection

Constant Substrate Protection
Job was expedited by Hurricanes Katrina & Rita
thermal insulation coating (TIC)
ceramic coating case study I
Diffuser
• Sugar mill diffuser was not cost
effective to conventionally insulate
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
• 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
thermal insulation coating (TIC)
ceramic coating case study II
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.
coatings for energy conservation
(commercial applications)
How Do The Coatings Work?
water treatment
Magnetic Field Units (MFU), conservation of
finite natural resources for fuel and water
treatment technologies.

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
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
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
WHAT DOES THIS MEAN…
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.
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.
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