Improving power efficiency—why not now?

Energy Efficiency: Improving Power Efficiency

Improving Power Efficiency—Why Not Now? Oxistop LLC

Youngstown State University Sustainable Energy Forum

June 8, 2010

welcome and thank you

Defining the opportunity

Introduction of the existing technologies

Benefits of the existing technologies

Recognizing obstacles

Overcoming obstacles

presentation objectives

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.

energy efficiency and conservation

Economic Realities

“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

Improving power efficiency—why not now?

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

Ceramic Coatings And Magnetic Field Technologies

• 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

Why Are The Technologies Not Being Used In The Power Utility Industry?

• 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

energy efficiency and conservation

Ceramic Coatings And Magnetic Fields What Are Some Of These Technologies?

high emissivity ceramic coatings

improving fuel efficiencies in various industries

reducing slag and residue buildup

resisting corrosion and erosion

preventing oxidation of boiler tubes

Ceramic boiler tube coatings improve power generation and reliability of the boiler

while reducing emissions.

ALL CRITICAL TO EFFICIENCY AND AVAILABILITY OF POWER GENERATION EQUIPMENT

Base metal

Procera™ Coating

Slag buildup creates many problems, including loss in boiler efficiency, potentially damage to the

unit and danger to personnel from falling slag.

slag challenges & coating solutions

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

Oak Ridge National Laboratory U. S. Department of Energy

corrosion challenges & coating solutions

furnace gas (pyrite)tube metal oxide

slag

sulfide corrosion

sulfides

Challenges: Oxidizing High Sulfur Conditions

Solution: Ceramic Coatings—Protective Layer

tube metal Ceramic Coating

slag furnace gas (pyrite)

Pro

cera

™ M

C19

-GR

P—

Pro

tect

ive

Lay

erCeramic Coatingprovide a “protective layer,” through complete chemical and mechanical bonding to the tube’s surface

corrosion challenges & coating solutions

AEP ceramic coating case study(how does this work)

American Electric PowerPicway Power Plant

(2004-2005)

AEP ceramic coating case study

Before coating install, burner with upper

eyebrow

Trial burner grit blast surface preparation

Trial burners with ceramic coating applied

First Installation.Trial area around burners to stop slag buildup

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

NRG Energy IncHuntley Power Plant

(2006-2007)

coating will lessen the thermal shock and damage to tubing

overall heat absorption in the furnace will improve

cost of application is below that of other corrosion coating options

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NRG ceramic coating case study

payback for the cost…24 DAYS

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

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Results

Associated Electric Cooperative Inc

New Madrid Power Plant(April, 2008)

AECI ceramic coating case study

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

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

higher heat absorption rate

Economizer Outlet Flue Gas Temperature

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•U1 Current Run (Oxistop, 2008)

U1 Summer, 2007 (Control)

U1 Average Summer, 2004 – Winter, 2006–2007

1. Boiler Bank 2. Superheater 3. Combustion Chamber 4. Hot Cyclone Collector 5. Economizer

6. Air Heater 7. Dust Collector 8. ID Fan

coating application areas(a comprehensive approach)

High emissivity coatings for energy enhancement (Production Side)

Low emissivity coatings for energy conservation (Conservation Side)

low emissivity ceramic coatings

excellent thermal insulation at low thicknesses

eliminates Corrosion Under Insulation (CUI)

easy application to irregular surfaces excellent personnel protection

Ceramic thermal insulating coatings for energy conservation that reduce energy cost and

provide emission control.

conventional insulation

low emissivity ceramic coatings

What is the difference between conventional insulation and Thermal Insulation Coatings (TIC).

CUI

Difficult Repairs

Maintenance

Wear/Vibration

No Inspect Ability

Limited Protection

conventional insulation thermal insulation coatings

No More CUI

Easy Repairs/Touch Ups

No Regular Maintenance

Virtually No Wear

Total Inspect Ability

Constant Substrate Protection

Job was expedited by Hurricanes Katrina & Rita

thermal insulation coating (TIC)ceramic coating case study I

Diffuser

Substrate: Diffuser (sugar mill)Problem: CUI, Personnel Protection,

Heat RetentionReason: Needed to keep diffuser at

steady temp and protectpersonnel from burns

Starting Temp = 190°F (87°C)Post app. Temp = 110°F (43°C)DFT = 60 mils

Sugar mill diffuser was not cost effective to conventionally insulate

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

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Shell Heat Exchanger

Substrate: Shell Heat ExchangerProblem: 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.

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thermal insulation coating (TIC)ceramic coating case study II

coatings for energy conservation(commercial applications)

How Do The Coatings Work?

water treatment

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

Magnetic Field Units (MFU), conservation of finite natural resources for fuel and water

treatment technologies.

water treatment

Cooling Water Systemsand 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 Systemsand 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

WHAT DOES THIS MEAN…

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

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.

Tim Batton, President

Oxistop LLC • Salem Energy Solutions • Sáetech LLCPhone: 330-332-1111 • Cell: 330-885-0902

1413 Quaker Circle, Salem Industrial Park • Salem, Ohio 44460 • www.oxistopllc.com

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.