Goodmorning lectures and fellow collegues.

Have you ever wondered what’s behind the curtains in the elusive power industry?
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Where and how are waste products disposed?
And is this system efficient? And if not is there anything we can do about it
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My name is Fiona Fraser and today ill be be answering these questions and providing a solution to the
problem encountered. And who knows maybe in return well all benefit with reduced electricity bills!
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Introduction
The generation, processing, and disposal of waste is a historical one. These challenges have
continued to plague us to the extent that now the modernized man has observed a linear
relationship between waste generation and economic development.
The Power generation industry is one of the industries that continues to experience challenges in
the processing and disposal of their petroleum waste products. One of the most prevalent wastes
generated in the oil industry is what is referred to as oily sludge. This oily sludge is generated
from the Heavy Fuel Oil (HFO) or bunker C that is used by the GPL INC in the generation of
electricity.
Kingston 1power plant has a generating capacity of 22 MW and produces approximately 4000
Imperial gallons of oily sludge per month. This oily sludge is disposed of at this plant Inc. via
incineration. The Atlas 1200 SL BWS incinerator with a diesel adding system was introduced to
a number of locations including the Kingston 1 power plant to alleviate the accumulation of this
waste.(should have pictures).My proposal is based on implementing a heat recovery system by
designing an optimal heat exchanger to be retrofitted to this incinerator to covert waste heat into
useful work
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So what is the problem?
This marine Atlas incinerator currently is the main means of disposing the accumulated oily
sludge. However, this incinerator release exhaust gases at high temperature (250oC-300 oC) along
with harmful gases such as Sulphur dioxide, NOx and the famous carbon dioxide into the air.
This increases environmental impacts

and the energy that could potentially be converted to useful work is wasted.
Additionally, the heat requirements for the Kingston 1 power plant is currently supplied by the
auxiliary boiler and the exhaust boiler. Now, this auxiliary boiler requires diesel for its operation
which increases fuel consumption

and the exhaust boilers can only supply the plant heat requirements during engine operation
which can result in total plant shut down in the event of a failure during scheduled or
unscheduled maintenance. The heat requirements for a typical HFO fired powered plant are

 Preheating of HFO to make it combustible in engines

 Lubrication oil preheating

 Storage and day tank preheating heating

 Cooling water

 Feedwater system

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Main Objectives

 To investigate the potential for increased process efficiency of the Atlas Marine

incinerator at GPL Inc (Kingston 1) using rejected heat, thereby reducing costs and minimizing

the amount of waste heat that is released into the atmosphere.

 To design a cost-effective heat recovery system (heat exchanger) for the marine

Atlas incinerator at the Kingston 1 plant.

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Specific objectives

 To determine the most cost-effective heat exchanger for waste heat recovery from

the Atlas marine incinerator at Kingston 1 plant.

 To design the most efficient heat recovery system for optimal heat recovery
  To identify the advantages and disadvantages of a waste heat recovery system taking

into consideration economics, efficiency and environmental impacts.

 To reduce waste heat emitted into the atmosphere

 To reduce diesel consumption of the auxiliary boilers

 To provided redundancy in the heating process.

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Literature review

Waste Heat

The significance of energy efficiency is profound as it is a central subject in energy science and

is also an important concern of economic and political actors. For instance, the International

Energy Agency (IEA) anticipates that over 50 percent of CO2 emissions can be avoided through

energy efficiency. One way to boost the value-added per unit of energy expended is to use the

excess heat from the process to generate additional services like electricity or space heating.

Reciprocating engines are able to achieve efficiencies of approximately 30% . Therefore a large

amount of the input energy is not converted into useful energy, this waste energy (about 48%) is

given off through the exhaust system. This waste energy is diverted to the lube oil system (27

%) and 25 % through the cooling system via the water jacket. The highest temperatures and

waste heat quantity are achieved by the exhaust stream

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Waste heat Principle of operation

The recovery of waste heat can be facilitated by indirect means (without heat exchanger), or

indirectly i.e with the aid of a heat exchanger. The method used in this instance is indirect heat

recovery. This is where the two fluids are separated by a heat transfer surface that can be either

active or passive.

HEAT EXCHANGERS

Heat exchangers are the main machines used to transfer energy from one fluid to another

fluid at various temperatures and this improves energy efficiency within the operating systems.

In designing an efficient heat exchanger several things must be addressed such as source

temperature, material requirements, corrosive contaminants in source stream and source pressure

drops.

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SHELL AND TUBE

The shell and tube heat exchanger are one of the most commonly and popularly used heat

exchanger due to its flexibility in various applications. It is split into two main systems i.e the

shell side and the tube side. The two sides each have a flowing medium, with the cooling fluid

entering the tubes and the hot fluid entering the shell. These two mediums are not mixed during

the process since the tubes prevents this and such indirect cooling occurs, heat is then transferred

between the shell and tube because they are in contact thermally.
 These heat exchangers are categorized according to flow and number of passes in tubes.

These are the parallel, counter and cross flow, the heat exchangers are usually comprised of a

mixture of these flows.

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Advantages

The advantages of the shell and tube heat exchanger is usually mirrored against the plate

heat exchanger because these are the most common heat exchangers in industries.

 Scale formation is less frequent on shell-and-tube heat exchangers, which means

that cleaning periods may be shorter than on other heat exchange devices.

 They are cheap and have a long service life which only requires minimum

maintenance.

 It is better able to handle pressure drop than parallel plate heat exchangers and are

cheaper than parallel plate

Studies carried out by ( Teke, Agra, Atayılmaz, & Demir, 2009) shows that the most

efficient heat exchanger type is the counter-flow heat exchanger which has the highest value of

net gains equal to US$1,383,497. The counter-flow heat exchanger was also found to be the most

efficient.

Methodology

General Overview of Kingston 1 power plant

 Site inspection for general data on required pipe duct lengths and availability of

space for heat exchanger

  Heat requirements for the plant in processes such as preheating of engines, lube oil

and fuel.

 Gathering of data for sludge production over an extended period and other

information

3.2 Conduct literature review

 Literature on design concepts and calculations for shell and tube heat exchanger and

other issues related to topic.

3.3Design of shell and tube heat exchanger

 Carrying out a site survey to gather data on outlet temperature of exhaust gas, inlet

temperature of cooling water and the heat capacity flow rates for the exhaust gas and water.

 Decide on construction type of available heat exchanger using literature and

performance history

 Determine the log mean temperature difference, heat rate (q) and correction factor

 Determine the tube bundle dimensions

 Determine heat transfer coefficient on hot and cold side

 Determine total heat transfer coefficient

 Determine heat exchanger dimensions (tube lengths)

 Determine number of baffles

 Iterate

 Check the power consumption i.e the power it takes to force the flow through the

tube as well as the shell is adequate

 Iterate
 3.4 Economic analysis

 Preform economic evaluations /investment criteria eg ROI

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Anticipated benefits

It is expected that the implementation of this waste heat recovery system will align

with GPL Inc. overall strategic objective, of providing reliable service to its customers and

reducing/ maintaining operating costs. This waste heat recovery system will directly impact

the following areas

1) Reduce auxiliary boiler diesel consumption

2) Improve overall plant efficiency

3) Reduce total dependence on exhaust heat recovery system of gensets in the event

of failure and maintenance issues

4) A rebalancing/improvement in the carbon emissions due to the burning of oily

sludge in the incinerators by converting wasted heat into useful work

5) A reduction in the exhaust temperatures of the incinerators

Tasks Unit Unit cost($) Total($)

Purchase of data, Journals, periodicals, etc.

Access to Science direct website 6000 12000

Access to Research gate website 6000 12000

 Testing

 Oily sludge testing 30000

Materials

Paper 1 pk 500 500

pens 1 pk 1000 500

pencils 1 pk 300 300

   

   

Transportation  

taxi 2 mths 4000 8000

   

   

Utility  

Internet access 2 mths 10000 20000

Phone calls 2 mths 500 5000

Total   $88,300
Waste Heat Recovery System
Kingston
Project Lead 2/15/21
Project Start:

1 Feb 15, 2021 Feb 22, 2021 Mar 1, 2021 Mar 8, 2021 Mar 15, 2021 Mar 22, 2021 Mar 29, 2021 Apr 5, 2021 Apr 12, 2021 Apr 19, 2021
Display Week:
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ASSIGNED
TASK PROGRESS START END DAYS M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S
TO

Research Literature review on

Fiona 50% 2/15/21 3/14/21 28
Design of waste heat recovery

Site Inspection Fiona 100% 2/15/21 2/15/21 1

Data gathering on sludge product

Fiona 100% 2/16/21 2/22/21 7
and other information
Preform calculation on the required
Fiona 100% 2/23/21 3/12/21 18
heat exchanger for the incinerator
Perform Economic analysis for
Fiona 100% 3/13/21 3/16/21 5
Designed heat exchanger

Write final report Fiona 28

Present report Fiona

It is expected that the implementation of this waste heat recovery system will align with GPL
Inc. overall objective of providing reliable service to its customers and reducing/ maintaining
operating costs.
Conclusion

In conclusion It is expected that the implementation of this waste heat recovery system will align
with GPL Inc. overall strategic objective of providing reliable service to its customers and
reducing/ maintaining operating costs which in turn will be beneficial for us as a country.