In order to utilize heat in exhaust of engines usually recovery boilers are used to generate process steam. However in industries where steam cannot be used for process, there is a strong possibility that power at 400V & 50HZ can be generated through combined cycle route in following manner:
Generate superheated steam through waste heat recovery boiler and pass it through a steam turbine powering an Alternator. This type of project is feasible if the numbers/size of gas engines are such that 8-10 tons of superheated can be generated which can deliver 1.0-1.6 MWe of power.
If steam quantity ranges between 4-8 tons per hour then utilizing a combination of Expander coupled to electric generator is a viable solution. This system requires saturated steam preferably at 12.5 bar (g) which can generate 340 Kw/hr. This system is cost effective and simple to operate.
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DDFC has engineered manufactured & delivered 05 Nos. combined cycle projects. First one was for International Steels Ltd Karachi producing 1200 KW power while the latest project was completed in 2018 for Fazal Textile Mills Ltd Muzzafargarh utilizing exhaust from 07 engines. Superheated boilers delivering 10 TPH @ 17 bar (g), 370°C steam to MAN brand steam turbine producing 1600 KW power. DDFC has commissioned its first Expander unit at AA Spinning Mills Faisalabad. Waste Heat Recovery boiler connected to 05 engines produces 5 TPH saturated steam at 12.5 bar (g). Expander utilizing this steam to deliver 340 KW of power. |