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9th International Conference on Compressors and their Systems IOP Publishing IOP Conf. Series: Materials Science and Engineering 90 (2015) 012062 doi:10.1088/1757-899X/90/1/012062 Executive Survey 2014 [4], gas is the dominant energy source for manufacturing and accounts for 60% of use. Yet electricity prices are of particular concern because they represent the larger cost, with 66% of utility spend on electricity. In its survey, EEF found that the cost of electricity was the most cited energy challenge for UK companies over the next two years. Figures from the DECC Quarterly Energy Prices December 2014 report [3] highlight that the average price of electricity for the industrial sector, including Climate Change Levy, has risen by 108 per cent in real terms since 2003, and by 3.3 per cent in the latest year. Against this backdrop of rising energy costs, an opportunity was identified to reduce the energy costs of small to medium industrial steam users by enabling local, small scale power generation. Industrial steam boilers are typically designed to operate at higher pressures than required by the end use application. Generating and distributing steam at higher pressure offers two advantages: Firstly, the boiler’s thermal storage capacity is increased, helping it to cope more efficiently with fluctuating loads and minimising the risk of producing wet and dirty steam; secondly, smaller bore steam pipes can be used for distribution. Having distributed the steam from the boiler, its pressure needs to be reduced to that required by the application. This reduction is conventionally performed by a pressure reducing station comprising a pressure reducing valve and various items of ancillary equipment. An alternative approach is to pass the plant steam through a microturbine installed in parallel with a pressure reducing station, which allows the energy released by the resulting pressure drop to supplement the electricity supply (Figure.1). The outlet steam is used by the downstream application as in a conventional system. Figure 1. Proposed installation of system. A microturbine can generate high value electrical energy for the consumer to be fed back into the grid and consumed locally or exported. While this approach is used by large steam users, the opportunity identified is for smaller steam users with boilers typically, less than 6MWth. Industries with potential for using the Spirax Sarco TurboPower include food and drink, chemicals processing, pharmaceuticals and hospitals. 2. Outline Machine Specification 2.1 General Requirements A specification for the prototype machines was developed by the partner companies: The use of a microturbine should provide low cost electricity generation from low steam flows. To make an attractive investment, it must have low life cycle costs. For the widest application, there should be no possibility of steam contamination. To embrace the widest range of applications the microturbine was specified so as to have an electrical output power from the package of 50kW. By using two microturbines in one package a 100 kW unit was specified. 2PDF Image | IOP Science The Development of a Small High Speed Steam Microturbine Generator System
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