COGENERATION TRIGENERATION STEAM & SUPERHEATED W HEAT EXCHANGER ORC EMISSION WATER TREATMENT EMISSION MONITORING SYSTEM STEAM & SUPERHEATED ORC TURBINE HEAT EXCHANGER COGENERATION TRIGENRATION WATER WASTE HEAT RECOVERY HEAT EXCHANGER ORC TURBINETOO DEDUSTING SOx NOx ABATEMENT WATER TREATMENT TREATMENT EMISSION MONITORING CONTROL COMPRESSOR LINE MANAG CERAMIC FILTRATION WASTE HEAT RECOVERY - HEAT EXCHA ENERGY ON GLASS GLASS | AUTOMATION | ENERGY ALL IN ONE
Transcript
COGENERATION TRIGENERATION STEAM & SUPERHEATED WATER
QUALITY IS NEVER AN ACCIDENT.BDF INDUSTRIES, SINCE 1906.
PRODUCT LINES
MELTINGBDF industries Melting product line includes the complete glass melting and conditioning technologies for design and supply of furnaces, working end & forehearths. The range of products includes also the relevant equipment like oil and gas burners and firing system, air and exhaust reverse valve, batch chargers, forehearth glass mixers etc.
BDF Industries furnaces are engineered by high level of customization with focus on energy efficiency and the attention to the environmental impacts.
Long time experience skilled people work together in synergic team with young generation technician in order to offer a wide range in design, manufacture and supply of different furnaces types for production of containers, tableware, lighting ware and technical glassware.
FORMING BDF Industries glass container forming product line is the historical core business. BDF Industries is able to provide a wide range of machineries with a high level of production flexibility to meet the customers’ requirements.
With more than 65 years’ experience in glass forming field, BDF Industries can offer the complete range of IS machine including gob forming and delivery, ware handling, container and variable equipment. The glass forming machineries are fully designed and assembled in house by BDF Industries in Italy, which has relevant knowledge of production process of the most important glass manufacturers in the world (e.g. strong credentials for forming business in O-I, Saverglass, Sisecam, Vetropack, Vitro...)
Our R&D office is focused to find the best solutions applied into IS machines in order to match lower production costs for our Customers thanks to higher reliability and maintainability of our product. We continue to work towards research and innovations that will deliver genuine advantages in productivity and efficiency for our customers glass factories located in different area around the world.
AUTOMATIONThe automation team involved in the Glass Industries focuseds its activity in the engineering process and software, during reconditioning and retrofitting of all part of Glass Factory including: plant designing, installation and start-up, network configuration, control, staff training, customer service and remote assistance.
The experienced, qualified, passionate and customer-focused staff is there to add value for customers, partners and suppliers.
As part of its own philosophy, the team believes and operates in the sustainable development: the application of its carefully designed and implemented systems greatly save energy and relevant impact on the environment, thus improving the quality of life and the safety of the operators in the field as well as adding economic and social value to the community.
A fundamental key of success in the automatic control is the interlink with melting and forming teams which makes the final product completely fit with the Glass Factory requirements.
ENERGYThe large BDF Industries experience in the glass industry and automation makes us the more qualified counterpart when it comes to improve, re-qualify or reinvent a glass production plant.
To master the challenges of globalcompetition, our customers mustminimize costs, continually increase theproductivity of their systems and meetever-stricter environmental regulations.
Our innovative and ecofriendlysolutions help to conserve naturalresources, improve energy and capitalutilization and optimize processes.For our customers, this means lowerraw materials consumption, feweremissions, greater energy efficiency,lower costs and increased output.The experience into demanding environment as the glass industry is our key point to succeed around you.
We can all make a difference. By applying different type of technologies, BDF Industries is able to supply a full package of energy recovering and/or renewable energy systems.
Resources from waste: heat recoverysystem of waste gases to produceelectric energy via ORC turbine orsteam turbine. Waste gases treatment: dust filtration and waste gases chemical compounds abatement techniques.These are some package solutionexamples of what BDF Industries canoffer, develop, deliver and install.
SERVICEThe reliable and innovative partner for running glass making plants to maximize productivity, quality, reliability, maintain assets and contain costs.
BDF Industries has a Service organization dedicated to provide a complete spectrum of the highest quality service solutions to satisfy the needs of our clients from a single source. Our services support the entire product value chain from melting glass making to forming, filtering, energy facilities and automation.
The service product line includes installation & startup, upgrades of mechanical equipment and automation, technical assistance for repairing and overhauling, training, performance evaluation & long term service agreement, integrated maintenance management & diagnostic solutions and systems, spare parts.
The contents of service are the following: • Supply local qualified supervisors• Supply of certified end/or upgraded OEM (Original Equipment Manufacturer)
spare parts for all maintenance operations
• Performance of all equipment maintenance
• Repairs using state-of-the-art technology
• Optimization of Spare Parts inventory• On the job Training of local
maintenance and operation personnel
The BDF Industries service team supports the strategic goals of glass factory by stimulating growth in core skills and providing personalized programs for the glass industry.
The BDF Industries Learning Center in Italy and strategically located Service Centers offer a wide range of programs in technical courses. Our technical courses are presented by field-tested experts combining understanding of theory and practical experience.
The quality training provided is a prerequisite to improve the skills of operating and maintenance personnel, so as to assure knowledge, safety and higher equipment availability.
It is possible for BDF to generate compressed air with the same plant.This could be useful for payback reason in some countries.
COMPRESSEDAIR PRODUCTION
ENERGY TOWER CONCEPT WITH LOW FOOT PRINT IMPACTSUITABLE FOR GLASS MANUFACTURING PLANT• No interference with the furnace processes• Important annual energy savings• Electricity production• Small Installation area required• Quick payback is possible• No media high pressure involved in the process• Well known technology• 20 years lifetime technology• BDF technology is fully suitable and tested for glass manufacturing plant• BDF patented system to prevent heat exchanger from fouling• Possible integration with other BDF Industries products
BDF ENERGY
BATCHCHARGER
DEDUSTINGMIX BOX
HEATEXCHANGER
ORCTURBINE
DeSOx FILTER DeNOxCEMS
FURNACE
LFP (LOW FOOT PRINT)BDF has developed this Energy tower conceptto reduced the required installation area for the glass plant.
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HOT WATER PRODUCTION
CHILLED WATER PRODUCTION
THIS IS BDF BASIC SOLUTION FOR ENTHALPY RECOVERY.HEAT EXCHANGER COULD EASY GENERATE AN HIGH AMOUNT OF STEAM OF HOT WATER.
Short payback time, high efficiency.Some uses for this hot water/steam are:• Office heating• District heating• Sanitary water• Food industry usage• Cullet washing• Steam industrial usage
BY USING ABSORPTION UNIT IS POSSIBLETO EXPLOIT THE HEAT IN THE FUMES TO PRODUCE CHILLED WATER.
Absorption unit technology can determines the chilled water temperature,4-5 °C for Br-Li or 0°C from ammonia based absorption unit.The chilled water can be used for:• Air conditioning• Food industry• Store temperature control• Cooling for IS cooling system
Br-Li absorption unit need heat exchangerand evaporating tower installation to operate.
ENTHALPY RECOVERY ENTHALPY RECOVERY
COGENERATIONTRIGENERATION OPTIONBDF CAN OFFERS THE COMBINATION BETWEEN ELECTRICITY GENERATION, HOT WATER AND CHILLED WATER PRODUCTION. IN THIS WAY IS POSSIBLE TO BOOST THE PAYBACK.
USING ELECTRICITY, STEAM AND CHILLED WATER PRODUCED IN YOUR OWN PLANT CAN REDUCE MOREOVER THE PAYBACK TIME. FOR THESE REASONS THE BIGGER INVESTMENT IN INSTALLATION COSTS COULD BRING TO A SHORTER PAYBACK THAN A NORMAL ENERGY TOWER SOLUTION.
Other option that BDF engineering can offer are:• Distillation unit to produce distilled water exploiting the heat in the fumes.• Seawater cooling system that can produce bags of salt ready for selling.
CEMS
GLASSFURNACE
HEATEXCHANGER
HOTWATER
FUMESCOOLINGSYSTEM
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ENVIRONMENTALPROTECTION
ENVIRONMENTALPROTECTION
POLLUTANTS ABATMENT, NOx AND SOx ABATEMENT
SELECTED CATALYTICREDUCTION SCR
Involves reacting NOx with ammonia(NH3) or urea(CH4N2O) in a catalytic bed at the appropriate temperature. According with temperature windows there are several catalysts available. The most common are vanadium and titanium oxides(TiO2 and V2O5) embedded in ceramic or metallic substrate, or zeolites. The catalyst units are modular honeycomb structures. The operating temperature of the system are usually from 200°C to 500°C with the optimum between 300°C and 450°C.
SELECTED NON-CATALYTIC REDUCTION SNCR
Also known as thermal DeNOx, the oxides of nitrogen in the waste gases are reduced by reaction with ammonia or urea. The chemical reactions are the same of SCR system but take place at higher temperatures without the need for a catalyst. The operating temperature is in the range 900-1050°C and the optimum is around 950°C for ammonia and 1000°C for urea. For this reason in SNCR the reagent injection is closer to the furnace than SCR. 1-2 seconds are required to obtain a good efficiency from the reaction.
DRY OR SEMI-DRYSCRUBBER HYDRATED LIME
An absorbent reagent is introduced and dispersed in the waste gas stream. this material reacts with SOx (but also metals and acid species HF and HCl) to form a solid, which has to be removed by a filtration system. Is possible to inject the reagent directly in the fumes ducting or in a reaction tower or chamber for a more efficient process. This absorbent reagent is a powder (usually Ca(OH)2, NaHCO3, or Na2CO3)for dry scrubber, or a water solution of NaCO3 or Ca(OH)2 for semidry scrubber. In the glass industry the most common is the dry application that use Ca(OH)2 namely hydrated lime.
FILTRATIONPROPOSED FILTER SIZE
Flue gas volume(Nm3/h)
High TemperatureTechnology
CERAMIC CANDLE
Low TemperatureTechnology
FABRIC SLEEVE
10000-15000 C1 S1
15000-20000 C2 S2
20000-25000 C3 S3
25000-30000 C4 S4
30000-35000 C5 S5
35000-40000 C6 S6
According to heat exchanger models we can find 12 different filers that can be used with the same volume of the waste gasses.
Dust efficiencyremoval
Possible re-use of collected dust
Pressure drop
Reaction to moisture
Temperature of Exercise Energy use Investment
costSafetyissue Size Re-heating
for DeNOx
SLEEVEVery high
Capture metals
Yes
Collected in dry conditions
High if not cleaned Bad Max
220 °C
Low, unless high
pressure drops
€ None Small Yes
CERAMIC CANDLE
High also with high dust loading, but low with small
particles
Yes
Collectedin dry
conditions
Moderate Good Over500°C
Low,unless high
pressure drops
€€
difficult explosion relief for
flammable materials
Small No
FILTRATION - DEDUSTINGBAG FILTERS SLEEVESBasic principle is to select a fabric membrane which is permeable to gas but retain the dust. Initially dust is deposited both on the surface fibers and within the depth of the fabric, but as the surface layer builds up, it itself become the dominating filter medium. This “cake” of dust increase also the resistance to gas flow, so periodic cleaning of the filter are mandatory to prevent the pressure drops.
HIGH TEMPERATURE FILTER MEDIA CERAMIC CANDLESSame principles of bag filter but the filter material is ceramic (or stone wool in some cases) that can resist to higher temperatures: this device is called candle. Further technologies combine NOx removal by the embedding of catalyst in this ceramic candles.
MAIN GLASSPLANT POLLUTANTS
O OS
S
O
O O
N O NO O
N
NO
O O
H F
H Cl
Nitrogen Oxides - NOx
O OS
S
O
O O
N O NO O
N
NO
O O
H F
H Cl
Sulfur Oxides - SOx
O OS
S
O
O O
N O NO O
N
NO
O O
H F
H ClFluorides - HF
O OS
S
O
O O
N O NO O
N
NO
O O
H F
H Cl
Chlorides - HClECOLOGIC
GLASSPLANT
NOx AND SOxBDF SYSTEMABATEMENT
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ENVIRONMENTAL
BDF CEMS 87• Devices for extractive and in-situ emission measurement• Measuring technologies (e.g. NDIR, UV, electrochemical or paramagnetic principle,
filter correlation, scattering light)• Single and multi-component analyzers, on customer request• Certified system by government agency• CEMS system can be integrated in plant control scada system• Low maintenance costs• Possible integration with process control.• Possible supervision integration with other glass plant controls.• Possible installation at ground level (fast-loop option).
EMISSION MONITORING
IN - SITU FAST LOOP IN - SITU FAST LOOP IN - SITU FAST LOOP
BDF INDUSTRIESNorth America LLC800 Town and CountryBoulevard - Suite 300770261 Houston - Texasphone +1 832 404 2292
BDF SERVISD.O.O.Hum Na Sutli 107/4,49231 Hum Na SutliCroatiaphone + 385 (0)49 382 222www.bdf.it
BRANCHES REPRESENTATIVES WHERE BDF INDUSTRIES IS ACTIVE
BDF ALL IN ONE MELTING FURNACE CONDITIONING WORKING END FOREHEARTH FORMING DELIVERY FORMING IS MACHINE WARE HANDLING ENERGY ON GLASS INDUSTRIAL AUTOMATION 12
