Ciragan Kempinski Hotel
By use of trigeneration system, which generates 1.4 MW electricity and 1,9 MW
heat, 970kW cooling is obtained from waste heat. By heat recovery, which is
generally ensured from the non-utilized oil cooling system, the outdoor swimming
pool is heated to 24°C in winter.
The system, which was put into operation in 2001, ensures an average energy
saving of € 400.000 in a year and contributes to the protection of the
environment by enabling CO2 reduction of 4.780 tons with a natural gas saving of
930.000 Nm3 by ensuring quality energy on constant basis.
Tata Steel Turkey
Tata Steel performs the manufacturing of painted steel sheet in its factory,
which is located in Adapazarı Hanlı OSB. The sheets, which are cleaned up in 7
pools by the help of cleaning process, are painted and the process is completed
after drying the painted sheets in furnace at a temperature of 300 °C.
The water is boiled in 7 pools by 7 boilers, each of which is 200 kW, and the
waste heat of 20 percent of the exhaust gas is reduced from 220 °C down to 120
°C by the use of heat recovery system and then the pool water pre-heating is
performed and the lacking temperature was ensured by the burning of the said 7
boilers.
% 100 temperature of the exhaust (47.000 m3/h) of the exhaust is reduced from
230°C down to 100°C by the use of the newly built 1 TEV®-KZ special exhaust
exchanger of 300 m2 and the in-pool temperature of 225 tons/h water flow rate is
ensured to be 60 - 70°C. While 300.000 kcal/h heat is recovered before the
project by the use of TEV®-KZ application, in total some 2.212.000 kcal/h heat
recovery is ensured.
As a result: Some heat recovery difference of 1.912.000 kcal/h is ensured.
(1.912.000 / 9250/0,65 x 5 x 50 x 24= 1.908.025 Nm3/year) fuel saving and
annually 820.450.-TL/year additional fuel cost is reduced.
At this point, still additional fuel saving will be achieved by ensuring the
pre-heating of the fresh air input into the furnace with the waste heat released
into the air by 100°C 16.000 m3/h exhaust.
At this point (47.000 x 1,2 x 0,35 x (100 – 35)) / 9250 / 0,65 x 5 x 50 x 24 =
1.280.000 Nm3/annual fuel saving will be ensured and 550.500.-TL/fuel cost will
be reduced.
By an investment sum of only TL 400.000, TL 820.000, that is 1.900.000 Nm3 fuel
saving was ensured and the investment made financed itself after only 6 months
and started making profit.
Arı Tekstil
In the painting and chemical finishing facility of Arı Tekstil, production is
performed by a capacity of 20 tons/day. 7-8 bars of steam, which is needed by
the process, is ensured by 1 coal fluid-bed steam boiler of 14 tons/day.
Burning/combustion parameters of the steam boiler does not operate on the basis
of real measurement and as emission values cannot be controlled, there were some
operational and environmental problems.
2 coal feed valves at values of 7,2 tons/h – 8,3 bars - 175,6 °C work at 25,9%
feed load and coal feed were ensured at a capacity of 1,7 KG/VALVE CIRCLE –
VALVE.
As a result: By 1.989 kg/h coal consumption, Q= 7200 x (852 – 102)= 5.400.000
kcal/h heat is produced by use of coal with thermal value of 3200 kcal/kg.
For controlling the burning, required parameters are obtained by burning
efficiency control by mounting Oxygen and Carbon Monoxide sensors.
For the boost of burning efficiency and increase of thermal value, fuel saving
was ensured by use of TEV-MAG thermo-magnetic fuel saving system.
1 coal feed valve at values of 7,2 tons/h – 8,3 bars - 180.6°C works at 25,9%
feed load and coal feed were ensured at a capacity of 1.7 kg/ 1 valve circle.
As a result: 5.605.920 kcal/h heat is generated by some coal consumption of 7,7
x45x0,25x60 = 1.101 kg/h.
B= 5.605.920/1.101 B=5.091,6 kcal/kg
Fuel saving ratio = 1- (1/(5.091,6 / 2.717)) = 46,6 %
Also, electricity consumption was reduced by 50%.
Some investment of TL 500.000 was made for achieving 46% coal saving, some
annual saving of TL 800.000/year was ensured and the investment was able to
finance itself after a period of 6 months and started making profit.
Elba Bant Project 1
Some fuel saving of 25% was achieved by use of TEV-MAG Thermo-Magnetic fuel
saving in the 2.6 MW natural gas-operated steam boiler. After putting the system
into operation one 0,7 MW natural gas-operated Hot Oil Boiler was deactivated
and therefore, additional fuel saving and electricity saving was ensured. After
the project, some annual natural gas saving of 300.000 Nm3 and 540 tons of CO2
decrease was ensured along with environmental contribution.
Elba Bant Project 2
Some fuel saving of 35% was achieved in the 2.6 MW natural gas-operated steam
boiler thanks to TEV-KZ, and in the 2.1 MW hot oil boiler by use of TEV-MAG,
TEV-KZ fuel saving systems. Exhaust temperatures of steam boilers and hot oil
boilers were decreased from 240°C down to 45-50°C, and the recycled exhaust
temperature was used during hot water production of 60°C and decreased the need
for hot oil temperature and allowed the closure of one 1.15 MW hot oil boiler.
As a result, additional fuel and electricity saving was achieved. After the
project, some annual natural gas saving of 400,000 Nm3 and 720 tons of CO2
decrease was ensured along with environmental contribution.
Denim Village
Some fuel saving of 20% was achieved by use of exhaust temperature recycling
system and 150 tons (24-60 °C) hot water saving was achieved in the 4.5 MW
natural gas-operated steam boiler by use of the TEV-KZ Thermo-condenser fuel
saving system. After the project, some annual natural gas saving of 300.000 Nm3
and 540 tons of CO2 decrease was ensured along with environmental contribution.