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THE FOLLOWING DIAGRAMS SHOW THE ERK DESIGN OF A THERMAL OIL HEATER THAT HAS ALREADY BEEN IN USE FOR 20 YEARS
DGA IS A LONG STANDING LICENSEE OF ERK AND OFFER THE FOLLOWING VIA FRASER ENERGY :-
• A 11 MWth BIOMASS FIRED THERMAL OIL HEATER WITH AUTOMATIC GAS IGNITION
• DESIGNED AND BUILT TO ASME 1 CODE. NOTE LOW PRESSURE DESIGN @ 5 BARG
• DESIGNED FOR THERMINOL 66 SYNTHETIC OIL
• BIOMASS FIRING IS BY WATER COOLED VEE GRATE, WITH FUEL SPREADER STOKER, ASH DISCHARGE TO WET ASHCONVEYOR . WATER COOLING TO BE INTEGRATED WITH STEAM GENERATOR.( NOT WORKED OUT YET)
• PROPANE GAS IGNITOR FOR AUTO IGNITION. IGNITOR FROM UK MANUFACTURER
• ~20 MINUTES FUEL STORAGE IN HOPPER ABOVE GRATE
• ‘ECONOMISER’ AND AIR HEATER TO PRODUCE ~ 83- 85% EFFICIENCY ON A NET BASIS DEPENDENT ON FIRING CONDITION
• BAG FILTER SYSTEM WITH TWIN FILTERS EACH CAPABLE OF OPERATING WITH THE OTHER ISOLATED FOR PART LOAD.
• NORMAL STACK ARRANGEMENT SHOWN, OTHER OPTIONS AVAILABLE
THERMAL OIL HEATER
BIOMASS FUEL HOPPER
AIR HEATER
CYCLONETWIN
VEE GRATE
WET ASH
TYPICAL ELEVATION OF THE 11 MW HOT OIL HEATER (ERK DESIGN) SK 01
BAG FILTERSTWIN
ASH BIN
TYPICALELEVATION OF THE THERMAL OIL HEATER SHOWING ACCESS ETC SK 02
Arrangement can be adjustedTo suit the site conditions.
TYPICAL PLAN VIEW OF THE THERMAL OIL HEATER SHOWING ACCESS AND ASH HANDLING
SK 03
BIOMASS FIREDOIL HEATER
AIR HEATER&
ECONOMISER
CY
CL
ON
ES
BAGFILTERS
ASHCONTAINER
STACK
ID FAN
SA FANPA FAN
Oil in
Oil out
Oil in‘One Pipe’ ‘One Pipe’
Heat extraction pipes 60.3 OD x 3.6 thk.Manifolds segregated by slide in baffle plate.This diagram shows each pipe with 14 verticalPasses but the number of passes and the tubeDiameter are set by ERK according to thegeometry of the heater..Monitor flow on all discharge pipes (~14 off separate flows)
SK 4BACK TO ERK DESIGN
TYPICAL DIAGRAM
OIL HEATER 11 MW
Eco 1
MainHeater
STEAMBOILER
OIL RECIRC PUMPSWITH FILTERS
M
3 – 24 KG/S PUMPS
2 X 5 KG/S PUMPSTHERMALOIL TANK
EXCLUDED
STEAM5050 KG/H@ 7 BARG
TWIN THERMAL OIL CIRCUIT SHOWING CONNECTION BETWEEN HEATER, STEAM GENERATOR AND ORC
SK 05
COMBNSYSTEM
BAGFILTERS
240 - 310 C
FG AIRHEATER*
<210C
66 KG/S – 1.8 MWE37.7 KG/S – 1.4 MWE
SOLID FUEL
SA (& FGR)
PA
ID
FIRING CONDITIONS
18 CHP Conditions at heaterinlet & outlet terminationpoints
Flowratekg/s
Supplytemp
0c
returntemp
0c
Normal operation –ORC~1400 kWe with steam
37.7 310 210
Steam production only 37.7 240 210
Restricted power production~1400kWe only (no steam)
37.7 310 236
Maximum power only~1800kWe (no steam)
60 310 250
~ 230 C
205 C
230 – 250 C
2.8-3.5 kg/s
37.7 – 60 kg/s
TO ORC POWERPLANT
130 C230-250C
DP
DP
M
OIL FLOWCONTROL
MINOR CCT
MAJOR CCT
A B C D E F G
1
2
3
Control Room and SwitchroomFully assembled in works beforeshipping
Ladder frame dischargerOn Live Fuel store24 hr fuel capacityNot included
SKETCH PLAN OF PLANT THERMAL HEATER FITTED TO AVAILABLE SPACE
SK 06Rev 1
Co
ntro
lR
oo
m
SK 07
DGA Combustion Grate
Tx Thermal oilInlet
~ 230 C
Thermal oilOutlet
~ 250 – 310 C
Water cooledcircuit
P
Tx
T
INDEPENDENT PIPE FURNACE (ERK LICENCE)
NoteThe Haz’ops people believe that the gratecannot be cooled by thermal oil primarilyas the connections to the grate are byflexible hoses.Comment on this proposition are invited asoil burners on most utility boilers use flexiblehoses for hot fuel oil
P
Tx
T
P
Tx
T
P
Tx
T
P
Tx
T
Tx
T
AIR HEATERECO 2
Temp gg
Press gg
T/C in pkt
Commissioningorifice
RETURNS FROMOTHER PANELS
TO OTHERPANELS
FLUE GAS FROMHEATER @ ~360 C
TO BAG FILTERS@ 205 C
P
T
15 independent flow lines
FRONT ELEVATION OF PLANT IN BUILDINGAPPROXIMATE
7
Stack 25 m height5 metre above building
ASH BIN
SK 08Rev 1
ERKA number of pipes manifolded together
So blockage in 1 pipe not easily detected
DGA/UNIQUIPMODIFIED
PROPOSED ALTERNATIVE ARRANGEMENT API COMPATIBLESK 09
API USE A SINGLEPIPE DESIGN AS ABOVE
Tx Thermal oilInlet
~ 120 – 215 C
DGA Combustion Grate
DGA THERMAL OIL HEATER (ERK LICENCE)
Backwall
Thermal oilOutlet
~ 250 – 310 C
ECO 1
ECO 3
SK 10
Water cooledcircuit
P
Tx
DP
T
P
Tx
T
THREE PIPE FURNACE
For 3 and 4 pipe systemsAssume the appropriatelines are provided withsame interlocks and gauges
Tx
DP DP
P
Tx
T
NoteThe Haz’ops people believe that the grateCannot be cooled by thermal oil primarilyAs the connections to he grate are byFlexible hoses.Comment on this proposition are invited asOil burners on most utility boilers use flexibleHoses for hot fuel oil
Tx Thermal oilInlet
~ 120 – 215 C
DGA Combustion Grate
Thermal oilOutlet
~ 250 – 310 C
Water cooledcircuit
P
Tx
T
SIX PIPE FURNACE (ERK LICENCE)
NoteThe Haz’ops people believe that the grateCannot be cooled by thermal oil primarilyAs the connections to the grate are byFlexible hoses.Comment on this proposition are invited asOil burners on most utility boilers use flexibleHoses for hot fuel oil
P
Tx
T
P
Tx
T
P
Tx
T
P
Tx
T
P
Tx
T ECO 1ECO 2
SK 9.1
Temp gg
Press gg
T/C in pkt
Commissioningorifice
T
T
T
TT
T
SK 10UNIQUIP API STYLE DESIGN
This style recommended by Uniquipas meets best practice in oil/gas industry.Oil passes through 6 parallel pipes through‘economiser’ then fired heater
Heat flux increase in Eco by plate welded totubes similar Greens Economiser
Oil temperature continuously monitoredby thermocouple In pockets. No flow measure
If heat flux in Eco too high, fins not installeduntil temperature lower
Membrane wall has been adopted, pendingstrength calculations
From Eco 1
SPREADER STOKER INSTALLATION
SA NOZZLES AND MINOR PENETRATIONS
FURNACE DETAILSACCESS TO THE FURNACE ISBY WITHDRAWING THE GRATE
SK10.1
SIX PIPE DESIGN
SK 11FIRED THERMAL OIL HEATER BY BIOMASS ON VEE GRATE
PLAN OF PLANT THERMAL HEATER
A B C D E F G
1
2
3
Control Room and SwitchroomFully assembled in works beforeshipping
Ladder frame dischargerOn Live Fuel store24 hr fuel capacitysat steam boiler only
SK 06
Thermal oilInlet
~ 120 – 215 CDGA Combustion Grate
DGA THERMAL OIL HEATER (ERK LICENCE)
Sidewall
Sidewall
Sidewall
Sidewall
Sidewall
Frontwall
Backwall
Intwall
Thermal oilOutlet
~ 250 – 310 C
FURNACE ENCLOSURE
ECO 1
ECO 3
SK 04
Water cooledcircuit
Recommended