Utilities & HR Applications

www.alfalaval.
com
Alfa Laval
Heat Recovery, Energy,

Water & Maintenance
savings opportunities
Ismail Uzman
Agenda :
Introduction to Utilities and where opportunities are.
1. Heat Recovery Waste Energy savings
2. Water, Energy and Maintenance savings
3. In what industries can savings be found?
4. Within the industries Where a the opportunities: in Utilities?
5. Within the Utilities Where are the opportunities: Fluids & Utilities
6. Utilities - Equipment
7. Utilities Equipment & Applications in an Industrial plant
Heat recovery: Where and how ?

8. Savings opportunities: Heat Recovery in an industrial plant
Other savings: Where and how ?

9. Savings Opportunities: Water, Energy & Maintenance
10. Summary
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Agenda Savings opportunities:
8. Heat recovery opportunities:

a. Heat recovery with Cooling Tower
b. Heat recovery with Compressor3.
c. Heat recovery with Steam generator
d. Heat recovery with Waste water
9. Other Savings opportunities:

a. Interchanger safe process / low maintenance
b. Shell & Tube replacement low maintenance
and higher efficiency
c. Chiller by pass with less energy consumption
d. Cooling tower replacement preserve water consumption
f. Alf filter Lower maintenance/free cooling
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Waste Heat, example Europe

Many industries generate large quantities of surplus heat that
are not used = waste heat.
More than 50% of primary energy is lost as waste heat. The

value of this heat is 500.000.000.000 Euro/year.
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Utility Heat recovery is the use of Heat

exchangers to utilize waste heat from a source
to heat or preheat fluids in another indirect
process in order to
preserve waste energy and reduce cost!!
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Heat recovery from Low- and/or High-grade heat:
90
C
80 High-grade heat ~ 60-90C
Heating of buildings
70
60
50 Low-grade heat ~ 15-60C

Direct- or preheating of tap water
Preheating of process water
40
30
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Energy and cost savings is found is found when:
Energy cost in kWh over a

period of time for
The Alfa Laval Heat exchanger < running an alternative
solution investment
equipment*
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*Not including environmental savings

2. Water, Energy & Maintenance Savings
Besides Heat recovery opportunities we also look into:
- Preserve water consumption
- Reduce maintenance
- Energy savings on efficiency..
and environmental benefits!
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3. In what industries can Utility Savings be found
Process Segments:
Metal/Mineral process
Inorganic chemical process
Pulp & Paper process
Refineries
Food and beverage
Industrial Manufacturing
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4. Within the Industries where are the
opportunities & applications?
Typically found in Utilities

Definition:
Utilities (or auxiliary cooling/heating) is the use of
utility fluids to cool /heat
-the secondary circuit
-indirect processes
..and equipment that are required to support the
core production processes in all type of industries.
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5. Within the Utilities where are the
opportunities and applications?
Fluids: Liquids that Utilities: The use of utility fluids

are not related to process. to cool/heat indirect processes.
Typically sold via Typically direct to
SYSTEM BUILDERS. END USER - UTILITIES MANAGER:
1. Hydraulic oil 1. Cooling Tower Water 29/35 32/37
2. Lubricating oil 2. Chilled Water 12/7 (10/5)
3. Thermal oil 3. Refrigerants: Ammonia or Freon
4. Transformer oil 4. Sea water 25/30
5. Cutting oil 5. River water 25/30
6. Water / Glycol 6. Waste water
7. Air 7. Steam 133 (160)
8. Hot water for space heating 90/70
9. Hot tap water, showers & washing 10/60
10. Compressed Air 6 www.alfalaval.com
bar
6. Within the Utilities what equipment
can be used with HEX technology?
Cooling Towers Air Steam generators Hot water Chillers

Compressors Boiler
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7. Utility Equipment & Applications found in a plant!
Buying behavior Buying behavior
Cooling
Utilities Manager: Towers Process Engineers:
- Maintenance/shared service dept - Linked to core process
- Auxiliary equipment - Technical consultants
- Often outsourced to 3rd party - Process industry contractors
- Directly with Alfa Laval PTD
Alf
Filter
Fluid Cooling:
- H2O, Oil, Glycol
Chiller Steam
Generator
Process Water Cooling
- Interchanger Boiler
Heat recovery from return
Air Compressor
Hydraulic Power
Unit
Heat Recovery:
- Utility Space heating Uninterrupted
- Utility Tap water heating power supply unit
Alfa Laval www.alfalaval.com
8. Heat Recovery opportunities
Utility Heat recovery

Opportunities
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8. Heat Recovery Savings in Energy: kWh
Assumption:
Cost savings = Cost for energy kWh:
Double ie
192 if
12 months ?
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8. Heat Recovery Savings in Energy: kWh
Assumption:
What is the cost of energy in your country ?

Example: Cost of fuel, to produce 1 kWatt of heat.
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Heat recovery if it can be utiliised
Eg: Domestic hot water pre heating or
space heating
Menu www.alfalaval.com
8. Heat Recovery opportunity
Cooling Tower (acting as heat source)
10 dC From mains
Before
Heat Recovery: 10 60 dC
After Heat recovery
10 dC From mains
Tap water,
Showers
20, 10 , 5 m3/h Heat 60 dC
cost
Kitchen etc
Boiler Tap water pre-heating
25 dC 35 dC
30 dC After HR: 30 60 dC
Waste
heat
40
20
10
m3/h
31-34 dC
X
35 dC 35 dC 37 dC
100 Oil cooling
m3/h
29 dC 29 dC 31 dC
Before Heat recovery www.alfalaval.com

8. Heat Recovery opportunity:
Cooling Tower Savings
Assume we bypass 40 m3/h CT side:

Load hot = Load cold = m x cp x dT
Load= 40m3/h(=40 000 kg/h) x 1 x (35-25)
Load=400 000 kCal = 465,2 kW
Load = 465 kW
GPHE design:
Delta T Hot side (CT side) 40 m3/h 35->25 GPHE design:
Delta T Cold side (HR side) 20 m3/h 30<-10 40 m3/h 35->23
20 m3/h 33<-10
Cost savings based on 465 kW:

Effect Cost Cost Hours Cost Days Cost Months Annual
Effect used kW/h per per per per per per Saving
1 hour hour day Day Month Month Year
kW kW/h Euro Euro Euro Euro Euro
465 465 0,1 46,5 8 372 20 7 440 6 44 640
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8. Heat Recovery opportunity:
Cooling Tower Savings & Payback
Before HR: 10 60 dC
After HR: 30 60 dC ; 465- 116 kW recovered!
kW Investment Annual Monthly Months

Cooling Tower Heat R ie Total cost Savings Savings Pay back period
kW/h Euro Euro Euro
80 Taps 20 m3/hr 465 8 559 44 640 3 720 2
40 Taps 10 m3/hr 232 7 258 22 320 1 860 4
20 Taps 5 m3/hr 116 6 403 11 160 930 7
Tap
Annual
Water 8 h / day
ie 12
flow 20 d / m
months
6 months
Additional savings:
- 10, 20 or 40 % relaxed load on Cooling Tower
- Less pump costs
- Less fouling & Maintenance
- Less water cost www.alfalaval.com
Example 1
Customer has CT 33 to 27 Deg C, 30 m3/hr

Q>I want to heat tap water 10 to how much?
A> You can heat the water up to 2 deg c approach.
You can heat the water to 31 deg C with CT 33 Deg
C, even 32 Deg C ie. 1 deg approach !
Every degree is saving !!!
Q> How much money will I save?
Calculations
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Example 1
Flow CT 30m3/hr 33 27
Flow Tap water ? Temp 10 31
Q=? M c dT= 30*6=180 kcal/hr divide by 0.86 = 209.3 kW
8hrs per day, 20 days per month, for 6 months
Saving for one year = 20.092 euro
Amount of water heated?

Q=209 kWatt
Q=m c dT
M = 8.6 m3/hr tap water heating.
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Example 1
But CT is 26 Deg in some months, what is saving?

CT 30m3/hr and we can heat the tap water 2 deg
approach, up to 24 deg C.
30 m3/hr 26 -- >20
Tap water 24 <-- 10
Capacity?
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I will preheat for you water 10 m3/hr from 10 to 24
deg C.
This is saving for you in 1 yr.
This is 150 kW
This is 15,000 euro in one year
Based on 8 hr day, 20 day month 6 month per year
opetn.
multiplying by 96 (always remember 96)
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Example 2
5 m3/hr heating water 10 deg c to 20

Saving= 5.575 euro /yr
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Example 2
5 m3/hr 10 20 is 58 kWatt saving

Or 15 25 in summer
58 kWatt saving is.
58*0.1cost *8 hrs * 20 days * 6 month = 5.500
eyuro per yr
(0.1*8*20*6=96)
Working operation 24 hrs a day 300 days a year
58*0.1 cost*24 hrs*300 days = 41.760 euro per yr
(0.1*24*300=720) www.alfalaval.com
Arguments
Reduction of emmissions becuause less burning of

LPG
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8. Heat Recovery opportunity Hot Oil:
Air Compressor Types 90 65 dC
Piston type w
Screw type w Radiator / Air cooling
Radiator/Air cooling
HOT OIL
HOT
Space / OIL
Tap water
heating
Space /
Heat recovery
Tap water
heating
Screw type Cooling Tower Water cooling Heat recovery
HOT OIL
More info..
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Air Compressor Inside a Screw compressor
Water cooled
Air 6 bar: Air 6 bar: Air 6 bar : To Plant
-Humid -Humid -Atm temperature + 10 dC
-Oily -60-70 dC
-60-70 dC
Air Inlet:
1 bar AIR or
Humid
20-30 dC
Oil
65-90 dC
Heat recovery..
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Air Compressor
After Heat recovery

54 dC
Office

5,4 Space
m3/h Heating
65 dC
60 dC 71 dC
5,4
m3/h Interchanger
Protects from
Dirt!
90 dC 40 dC
5,4 5,4
65 m3/h m3/h
dC 71 dC
60 dC 29 dC
Waste
Heat
To Before Heat recovery www.alfalaval.com
CT
Air Compressor Savings
Heat dissipation 72 kW from Compressor

Compressor load: 72 kW
72 kW (=62kCal/h) = 5,4m3/h x 1 x dT
dT = 11,5 dC
Heat recovery GPHE design:

Delta T Hot side (CT side) 5,4 m3/h 71->60 Compressor cooling need:
90 l/min = 5,4 m3/h
Delta T Cold side (HR side) 5,4 m3/h 54<-65
(from AC Broschure)
Cost savings based on 90 kW compressor w 72 kW heat dissipation:

Effect Effect Effect Cost Cost Hours Cost Days Cost Months Annual
Compressor Heat used kW/h per per per per per per Saving
dissip 1 hour hour day Day Month Month Year
kW kW kW/h Euro Euro Euro Euro Euro
90 72 72 0,1 7,2 8 57,6 20 1 152 6 6 912
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Typically 70-75 % of energy goes to waste in a compressor

Air Compressor Savings & Payback
Savings and pay back period on Compressor HR:
Compressor Heat Heat Investment Annual Monthly Months

Recovery dissipation Total cost Savings Savings Pay back
kW/h Euro Euro Euro period
90 kW Compressor 72 5 906 6 912 576 10
180 kW Compressor 144 6 527 13 824 1 152 6
360 kW Compressor 288 7 739 27 648 2 304 3
Heat 8 h / day 12
recovered 20 d / m months
6 months
Additional savings:
- Up to 100% relaxed load on Cooling Tower
- Less fouling & Maintenance
- Double annual savings on HR if used 12 months www.alfalaval.com
Steam generator Flash steam
After Heat recovery
Steam 133 dC / 3 bar abs

Tap water, Treated
Showers Before HR H2O
Kitchen etc 10-60 dC
Flash
10 dC
Steam
60 dC Waste !
From mains-
Flash Steam 1,2 bar
104, dC
Flash steam Condensate 1,16 bar
104 dC
Steam Condensate
traps Tank
104 dC
Condensate water & steam133 dC

Steam generator Flash steam
Assumptions: Steam generator 1 000 kW
Steam flowrate: 1 666 kg/h (from CAS design program)
20 % is the flash steam is 315 kg/h
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Flash steam HR - Savings
Effect Effect Effect Cost Cost Hours Cost Days Cost Months Annual
Steam Heat used kW/h per per per per per per Saving
Flash Recovered 1 hour hour day Day Month Month Year
200 200 200 0,1 20 8 160 20 3 200 6 19 200
Effect Heat Investment Annual Monthly Months

Steam flash Recovered Total cost Savings Savings Pay back
kW/h Euro Euro Euro period
200 kW 200 7 339 19 200 1 600 5
Based on
Based on
6 months - if
6 months - if
12 months 12 months
38 400 2,5
TS6M Months!
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Flash steam HR Correct HEX model
M6M Classic Plate Correct HEX model:

TS6M TS Plate
-Designed for liquid/liquid applications -Designed for steam/liquid applications

-Small ports -Large ports
-Limited gasket temperature performance -High gasket temperature performance
-Not optimal length/width ratio -Optimal length/width ratio
Evaporation www.alfalaval.com
Waste Water Textile Dye house
Textile dye process:
Wide gap
Plates:
Mechanical
filter
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http://www.ozenmensucat.com.tr/?sf=hksp&dl=en&st=smn
Before Heat recovery Steam 133 dC / 3 bar abs
Dye textile
Condensate
65 dC water 133 dC
Waste-Water
from dye textile 65 dC Flash
!! Steam
Steam Waste !
trap
Separator
65 dC Condensate
Waste Heat !! Tank
104 dC
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After Heat recovery
Steam 133 dC / 3 bar abs
Hot water to dye machine at 60 dC
Dye textile
65 dC Condensate
20 dC water 133 dC
Flash
Steam
Waste !
Steam
trap
65 dC
60 dC Separator
Condensate
20 dC Tank
104 dC
15 dC From mains
Assume we discharge 40 m3/h at 65 dC waste water :

Load= 40m3/h(=40 000 kg/h) x 1 x (65-20)
Load=1 800 000 kCal = 2 093 kW
GPHE design:
Delta T Hot side (CT side) 40 m3/h 65->20
Delta T Cold side (HR side) 40 m3/h 60<-15

2,093 2,093 0.1 209.3 8 1,674 20 33,488 12 401,856
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Wide-gap 200S SS NBR 167 pl

Textile Waste Water Heat Cost Cost Investment Annual Monthly Months
40 m3 65--> 20 Recovered GPHE Piping Total cost Savings Savings Pay back
kW/h Euro Euro Euro Euro Euro period
2093 2,093 50,000 40,000 90,000 401,860 33,488 3
Based on
12 months
8 hrs per day
operation
Additional savings:
Annual savings based on dye machinery utilisation capacity,
faster filling with ready made hot water:
> 1,000,000 per year
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Classic Plate Wide Gap Plate
-Designed for fibrous media

- Less contact points, less efficient
- Designed for fiber free liquid applications - Applications include:
- High efficiency many contact points - Orange juice
- Narrow gap, clean fluids - Sugar pulp
- Evaporation
- Textile waste water
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Other savings opportunities
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9. Maintenance, Energy & Water Savings
Other savings opportunities within:

-Preserving water consumption
-Reducing maintenance
-Energy savings on efficiency, Free cooling etc
and environmental benefits!
+
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9. Water, Maintenance or Energy Savings
Interchanger HEX
50 % Evaporation in 6 months 350 kW Cooling tower:

100 % Evaporation in 12 months - Average use: 5 000 m3/ year
Inter-
changer
35 dC X
37 dC 35 dC
Dirt Cooling tower dirt etc:
Fouling &
CaCO3/salt Maintenance Fouling = Less efficiency
Chlorides & more Maintenance
etc 29 dC X
31 dC 29 dC
Make up Water needs:

-Treatment chemicals
Interchanger other
Necessary to compensate
1. Protects plant functions?
- Evaporation -Heat recovery applications
- Flushing & discharging from dirt, fouling -Fluid is non H2O
of system -Pressure breaker
& legionella !! -Fluid temp too high 90-100 degrees
2. Saves maintenance !! -Control of heat balance in Plant
3. Saves water (less discharge www.alfalaval.com
less flushing)
Interchanger Dirt and Fouling
Cooling Tower dirt = Fouling

:
Debris Plastics etc
Biofouling Surface coating Scaling
& Legionella fouling CaCO3
Higher Cost:
-High Maintenance
-Maintenance
-Factory downtime
-Pumping
-Less Heat transfer
-Downtime
Efficiency!!
-Energy kW
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Interchanger Protects from Fouling
37 dC
35 dC X
35 dC
Dirt Debris Biofouling Coarse fouling Scaling/ CaCO3

CaCO3/salt
Chlorides
29 dC 29 dC
etc X
31 dC
No fouling
No maintenance!!!
Less pumping costs !!
High heat transfer efficiency
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Interchanger CaCO3 Calcium carbonate (Salt)
350 kW Cooling Tower Day 1: CaCO3 in loop is 100 ppm

dT is 7 dC,
Hence flow rate is 50m3/hr After 6 months CaCO3 in the loop doubles:
Whole system x 100 = 5,000 m3 50% of water evaporates. Minerals stay !
Replacement water is added by makeup!
5.000 m3=
5.000.000 Litres in the system
Water contains CaCO3 (salt) After 6 months: 200 ppm CaCO3
After 12 months: 400 ppm Ca CO3
Cost of water: 1,5 euro/m3
50 % Evaporation in 6 months (provided the system is not flushed)
100 % Evaporation in 12 months
35 dC
CaCO3 build up in loop

CaCO3
29 dC Reduce efficiency
Higher pumping costs
Make up Water to compensate for Evaporation Increase maintenance www.alfalaval.com
= Adds more CaCO3
Interchanger CaCO3 Calcium carbonate; Salt
50 % Evaporation in 6 months No evaporation!

100 % Evaporation in 12 months No CaCO3 salt build!
Flushing (empty system of water)
CaCO3 Salt build No flushing!
Limited IN THIS LOOP !! No maintenance!
Less pumping cost
37 dC
35 dC X
35 dC
CaCO3 CaCO3 build up:

-Less efficiency & more maintenance
CaCO3
29 dC 29 dC
X
31 dC
Make up Water
Less Make to compensate
up Water for
(with CaCO3)
Evaporation
& Treatment chemicals!!!
= Adds
Less more CaCO3
flushing Water
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Interchanger Chlorides & Corrosion
350 kW Cooling Tower Chlorides Corrosion:
5.000 m3 water in loop Adding make up water adds chlorides!!
Water contains Chlorides
In 6 months concentration doubles !
Corrosion Alfa Laval Heat exchanger?

At max. 50 Deg C <150 ppm Cl - Chloride AL use
Alloy 316 plate material in the heat exchanger.
At max. 50 Deg C>150 ppm Cl Chloride AL use

SMO 254 plate material in the heat exchanger:
- No crevice corrosion in AL plates!!
Chlorides
With an Alfa Laval Interchanger:
-Protect plant loop from corrosion
Make up Water to compensate for
Evaporation -Safe to use carbon steel in plant loop
= Adds more Chlorides instead of stainless steel.
Slide 52 www.alfalaval.com
Interchanger Chlorides & corrosion
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Interchanger Chlorides & corrosion
50 % Evaporation in 6 months No evaporation!

100 % Evaporation in 12 months No flushing (empty system of water)
Flushing (empty system of water)
Chloride corrosion No added Chlorides No corrosion
LIMITED IN THIS LOOP = Safe to use Carbon steel!
37 dC
35 dC X
35 dC
Chlorides Chlorides Corrosion

Chlorides
29 dC 29 dC
X
31 dC
Less
MakeMake up Water
up Water to compensate for
& Treatment
Evaporation chemicals
Less added
= Adds moreChlorides!!
Chlorides
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Interchanger Water consumption
No evaporation!
100 % Evaporation in 12 months Less water consumption:
Flushing (empty system of water) -No flushing or discharging !
CONTAINED IN THIS LOOP Less water treatment chemicals!
37 dC
35 dC X
35 dC
Evaporating
Evaporating Water loop
Water loop
w chemicals
29 dC 29 dC
X
31 dC
Make up Water
Less Water
& Treatment chemicals Smaller
for full loop
partial 5 000 m3
loop Water
loop www.alfalaval.com
Interchanger HEX Savings
Interchanger gives a separate circuit for the plant:

Protect the system the airborne debris and fouling coming into the plant
Protect the system from salt - calcium carbonate CaCO3
Protect the system from corrosion in plant loop ie avoid Chlorides
With an Interchanger safe to carbon steel in plant (instead of stainless steel).
Savings:
1.Easier to clean fouling in a GPHE than in plant loop:
Less Maintenance - Less factory downtime
2. Less pumping costs
3. Carbon steel in plant loop - cheaper than stainless steel
4. Less chemicals or H20 treatment consumption for CT
5. Less water consumption www.alfalaval.com
Shell & Tube replacement
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Assume: 10 000 liter hold up at 60 dC

Heat loss: 1 dC / hour
Q=m x cP x dT = 10 000 kCal/h = 10 000 x 1 x 1 = 11,6 kW
1 dC/h
60-59 dC 1 hr
Shell & Effect Cost Cost Hours Cost Days Cost Months Heat
Tube used kW/h per per per per per per Loss
Heat loss 1 hour hour day Day Month Month Year 6 Months
11,6 11,6 0,1 1,16 8 9,28 20 186 6 1 114
11,6 11,6 0,1 1,16 8 9,28 20 186 12 2 227
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Advantage vs
Can be up to 60% smaller and lighter.
Consume up to 60% less cooling water.

Have up to five times higher heat transfer capacity.
Have a self-cleaning effect, due to high liquid turbulence across transfer surfaces.
Have lower maintenance and operating costs, ensuring better long-term economy.
Have a low hold-up volumes allowing a more accurate temperature control.
No heat losses
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SAVINGS:
Less water consumption
Less energy consumption.
Less hold up volume fast response time
Less maintenance costs.
Less downtime
No heat losses
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Chiller by pass - 2 types of chillers
Water cooled condenser Air cooled condenser

by Cooling Tower: by Dry cooler:
7 dC 12 dC
Evaporator
Condenser
35 dC 29 dC
Both are very heavy on

Energy kW consumption
ie expensive to run!
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Chiller by pass - 2 types of by pass
Water cooled condenser Air cooled condenser
by Cooling Tower: by Dry cooler:
7 dC 12 dC
Evaporator
Condenser
35 dC 29 dC
Bypass possible with:

- Interchanger / HEX bypass
- Dry cooler
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Chiller by pass - Before by pass
Water cooled Condenser:
35 dC
Condenser Gas converts

H2O to liquid (condenses)
From 29 dC
mains 50 dC
Refrigeration
Expansion valve:
Liquid expands
Compressor:
Heats up Freon
kW/?
hence cools down to 2 dC
or NH3
2 dC
Liquid converts
To gas (evaporates) Evaporator
7 dC 12 dC
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Chiller by pass - After by pass
Summer: Winter:
35 dC 11 dC
12 dC
38 dC
Condenser
29 dC 32 dC 6 dC
7 dC
Interchanger: Interchanger:
Only protects Protects
Evaporator
process from Dirt &
from Dirt & By pass
Corrosion etc! 7 dC Chiller & 7 dC 12 dC
12 dC
reduce
running cost !!
(bigger HEX)
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Chiller by pass - Savings
The By pass with

Not only protects your plant from dirt
but also
Saves energy by reducing the
running hours of your chillers.
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Chiller by pass - Savings
Assumption:
1 1 0,1 0,1 8 0,8 20 16 6 96
Chiller Energy Effect Cost Cost Hours Cost Days Cost Months Annual
Heat consumption used kW/h per per per per per per Saving
transfer Effect 1 hour hour day Day Month Month Year 6 Months
1 000 * 200 200 0,1 20 8 160 20 3 200 6 19 200
2 000 400 400 0,1 40 8 320 20 6 400 6 38 400
What is the energy kW consumption of your Chiller ??

What is your Cost for maintenance ??
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*1000 kW=171 m3/h Temperatur 12 to 7 dC

Chiller by pass with Dry cooler
The by pass
Saves energy by reducing the
running hours of your chillers.
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Chiller by pass Before By pass
35 dC
29 dC
Condenser
With By pass
50 dC
Refrigeration
Compressor:
Heats up Freon
kW/?
or NH3
2 dC
Evaporator
12 dC
7 dC
Reduces kW
Reduce cost! www.alfalaval.com
Chiller by pass Dry cooler
No by pass
30 dC
Partial by pass
Complete by pass
5-10 dC 0 dC
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Chiller by pass Dry cooler Savings
By pass Energy savings kWh

per month/season:
Additional Savings:
Reduced wear and tear
on your chiller.
Less maintenance costs.
Less plant down time.
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Chiller Energy Effect Cost Cost Hours Cost Days Cost Months Annual
Heat consumption used kW/h per per per per per per Saving
transfer Effect 1 hour hour day Day Month Month Year 6 Months
1 000 * 200 200 0,1 20 8 160 20 3 200 6 19 200
2 000 400 400 0,1 40 8 320 20 6 400 6 38 400
What is the energy kW consumption of your Chiller??
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*1000 kW=171 m3/h Temperatur 12 to 7 dC

Example from an international

tyre manufacturer in Europe 2015:
Investment: Chiller bypass; Alfa Laval Dry cooler:

162 280
Annual savings based on less chiller runtime:

111 780
Pay back time on investment: 1,4 years

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Cooling Tower replacement Dry cooler
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* Combined with a Chiller dependent on temperature/fluid requirements

Cooling Tower replacement - Savings
Water savings?
Average annual water use for a 350 kW cooling system:
Traditional cooling tower: 4 to 5.5 million liters
Dry coolers use no water

Result: Dry coolers reduces consumption by of 4-5,5 million
liters of water/year
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350 kW Cooling Tower, 58 m3/h x 100 (loop amount)
5.800 000 liters water in loop
Cooling Tower replacement
Advantages of Dry cooler

vs
Cooling tower
No water consumption
Less maintenance required no fouling, no downtime
Excellent performance in dry application
No make up water treatment or chemicals necessary
Easy & cheap capacity control
No risk of Legionella
No risk of corrosion (thanks to closed water circuit and not water treatment required)
No steam generation during the winter
When to choose Dry cooler ?

-Competitive for Temperature approach (TOUT(Fluid) TAir) > 7 C www.alfalaval.com
Cooling Tower replacement - Adiabatic
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Cooling Tower replacement - Savings
Water savings?
Average annual water use for a 350 kW cooling system:
Traditional cooling tower: 4 to 5.5 million liters

Abatigo closed loop use 75-150 000 liters
Result: Adiabatic cooler reduces consumption by of 4

million liters of water/year
www.alfalaval.com
350 kW Cooling Tower, 58 m3/h x 100 (loop amount)
5.800 000 liters water in loop
Cooling Tower replacement
Advantages of Adiabatic cooler

vs
Cooling tower
Minimal water consumption

Less maintenance required No fouling, no downtime
Excellent performance in dry application
No make up water treatment or chemicals necessary
Easy & cheap capacity control
Minimal risk of Legionella
Minimal risk of corrosion (thanks to closed water circuit and not water treatment required)
No steam generation during the winter
When to choose Adiabatic Cooler?

-Competitive for Temperature approach (TOUT(Fluid) TAir) < 7 C www.alfalaval.com
9. Water, Maintenance & Energy Savings
Sea & River water free cooling
Alf
Filter
Alfa Laval www.alfalaval.com

ALF filter
Increase efficiency:
Protect against clogging &
fouling
Save energy:
Minimize pressure drop
on HEX and ALF
Cooling Tower or Chiller

replacement/supplement:
Free cooling opportunity

www.alfalaval.com
https://youtu.be/_MCv6qyBwoE
www.alfalaval.com
Increase efficiency - protecting against clogging & fouling

Such fouling and clogging can have serious effects, reducing the efficiency of heat transfer and limiting
the speed at which water can flow through the heat exchanger. This results in conditions in which
biological growths can flourish, and surface fouling caused by diminished flow velocities.
The Alfa Laval Filter (ALF) is a supremely cost-effective way to avoid all these problems and ensure a
reliable supply of clean cooling water. The system provides the major advantage of automatic flushing
carried out at regular intervals, without interrupting the filtering process or disturbing cooling operations
in any way. This provides crucial peace of mind for those responsible for process equipment
downstream from the ALF installation.
Reduce energy costs

The ALF also provides high filtering capacity with a low pressure drop, which cuts back on energy costs.
By also minimizing the pressure drop across both plate heat exchanger and filter, an ALF installation
helps reduce the overall costs of an effective cooling package. Because there are so few moving parts,
maintenance costs are also low.
- See more at: http://www.alfalaval.com/products/separation/automatic-back-flushing-filters/Cylindrical
filter-baskets/ALF/#sthash.MT2scVoh.dpuf
www.alfalaval.com
10. Save cost with Alfa Laval
Heat recovery opportunities:

a. Heat recovery with Cooling Tower
b. Heat recovery with Compressor
c. Heat recovery with Steam generator
d. Heat recovery with Waste water
Other Savings opportunities:

a. Interchanger safe process / low maintenance
b. Shell & Tube replacement low maintenance
and higher efficiency
c. Chiller by pass with less energy consumption
d. Cooling tower replacement preserve water consumption
f. Alf filter Lower maintenance/free cooling
www.alfalaval.com
Every kW recovered saves costs!

Every liter water saves cost !
Reduced downtime saves cost !
Less maintenance saves cost!
dont forget environmental benefits!
www.alfalaval.com
Thankyou !
www.alfalaval.com

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Heat Recovery, Energy,

Heat recovery: Where and how ?

Other savings: Where and how ?

8. Heat recovery opportunities:

9. Other Savings opportunities:

Waste Heat, example Europe

More than 50% of primary energy is lost as waste heat. The

Utility Heat recovery is the use of Heat

preserve waste energy and reduce cost!!

Heat recovery from Low- and/or High-grade heat:

50 Low-grade heat ~ 15-60C

Energy and cost savings is found is found when:

Energy cost in kWh over a

*Not including environmental savings

and environmental benefits!

Typically found in Utilities

Fluids: Liquids that Utilities: The use of utility fluids

Cooling Towers Air Steam generators Hot water Chillers

Utility Heat recovery

What is the cost of energy in your country ?

Before Heat recovery www.alfalaval.com

Assume we bypass 40 m3/h CT side:

Cost savings based on 465 kW:

kW Investment Annual Monthly Months

Customer has CT 33 to 27 Deg C, 30 m3/hr

Amount of water heated?

But CT is 26 Deg in some months, what is saving?

5 m3/hr heating water 10 deg c to 20

5 m3/hr 10 20 is 58 kWatt saving

Reduction of emmissions becuause less burning of

Screw type Cooling Tower Water cooling Heat recovery

After Heat recovery

Heat dissipation 72 kW from Compressor

Heat recovery GPHE design:

Cost savings based on 90 kW compressor w 72 kW heat dissipation:

Typically 70-75 % of energy goes to waste in a compressor

Savings and pay back period on Compressor HR:

Compressor Heat Heat Investment Annual Monthly Months

After Heat recovery

Steam 133 dC / 3 bar abs

Flash steam Condensate 1,16 bar

Before Heat recovery www.alfalaval.com

Effect Heat Investment Annual Monthly Months

M6M Classic Plate Correct HEX model:

-Designed for liquid/liquid applications -Designed for steam/liquid applications

Textile dye process:

Before Heat recovery Steam 133 dC / 3 bar abs

Assume we discharge 40 m3/h at 65 dC waste water :

Effect Cost Cost Hours Cost Days Cost Months Annual

Wide-gap 200S SS NBR 167 pl

Classic Plate Wide Gap Plate

-Designed for fibrous media

Other savings opportunities within:

and environmental benefits!

50 % Evaporation in 6 months 350 kW Cooling tower:

Make up Water needs:

Cooling Tower dirt = Fouling

Dirt Debris Biofouling Coarse fouling Scaling/ CaCO3

350 kW Cooling Tower Day 1: CaCO3 in loop is 100 ppm

CaCO3 build up in loop

50 % Evaporation in 6 months No evaporation!

CaCO3 CaCO3 build up:

Corrosion Alfa Laval Heat exchanger?

Utilities & HR Applications

Utilities & HR Applications