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Energy Saving and High Efficiency Cogeneration at HELLENIC FERTILIZERS

This case study explores the energy-saving measures and high-efficiency cogeneration unit at HELLENIC FERTILIZERS, a Greek fertilizers company. Learn about their innovative strategies to reduce energy consumption and increase efficiency.

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Energy Saving and High Efficiency Cogeneration at HELLENIC FERTILIZERS

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  1. HELLENIC FERTILIZERS AND CHEMICALS ELFE s.a.

  2. HELLENIC FERTILIZERS AND CHEMICALS ELFE S.A. “Energy Saving and High Efficiency Cogeneration in an Industrial Complex: The Case Study of HELLENIC FERTILISERS AND CHEMICALS ELFE S.A.” Dr. Theodora Kouloura Strategic Planning, Regulatory Affairs and Management Systems Dep. Manager

  3. OVERVIEW • The Greek Fertilizers Company • The energy system • Basic and On-going Energy Saving Measures • The high efficiency cogeneration Unit • Legislative difficulties in energy saving • Conclusions

  4. HELLENIC FERTILIZERS AND CHEMICALS ELFE s.a. The Greek Fertilizers Company (1/5) ELFE (formerly Phosphoric Fertilizers Industry) established in 1961 Initially, the final products were compound NPK fertilizers for domestic use. Over the next decades, the existing plants were substantially upgraded or replaced by new ones, while new plants were added.

  5. HELLENIC FERTILIZERS AND CHEMICALS ELFE s.a. The Greek Fertilizers Company (2/5) • The ELFE site at NeaKarvali, Kavala, consists of the following production plants and facilities: • Ammonia Plant (capacity 165.000 MTPY) designed and constructed by KTI Holland (now Technip) • Nitric Acid Plant (capacity 230.000 MTPY) classical Dual Pressure process, AN-solution Plant (capacity 280.000 MTPY), both of them designed and constructed by UHDE • Nitrogenous Fertilizers (AN/CAN) Plant (capacity 260.000 MTPY) designed by UHDE and constructed under the license from NORSK HYDRO (High temperature Pan Granulation process) • Phosphoric Acid Plant (capacity 75.000 MTPY P2O5), SIAPE–CHEMIEBAU-PRAYON technology

  6. HELLENIC FERTILIZERS AND CHEMICALS ELFE s.a. The Greek Fertilizers Company (3/5) • Two (2) Sulphuric Acid Plants (total capacity 430.000 MTPY), one using HUGO PETERSEN and the second DAVY McKee technology • Three (3) Compound (NPK) Fertilizers Plants (total capacity 500.000 MTPY). Two plants are using PEC technology/TVA process and the third is using UHDE – STAMICARBON technology • Ammonia sphere (nominal capacity 1.800 MT, usable 1.500 MT) • Atmospheric pressure Ammonia tank (capacity 15.000MT) (UHDE design) • Four (4) turbogenerators (installed power 21,218 MW) • Various facilities for storage of raw materials and final products • Two (2) bagging stations for NPK's and AN/CAN fertilizers respectively • Autonomous private port for loading/discharging final products and raw materials

  7. HELLENIC FERTILIZERS AND CHEMICALS ELFE s.a. The Greek Fertilizers Company (4/5) Operation Overview

  8. HELLENIC FERTILIZERS AND CHEMICALS ELFE s.a. The Greek Fertilizers Company (5/5)

  9. ELFE: THE ENERGY SYSTEM NATURAL GAS (1/3) NG AS RAW MATERIAL FOR AMMONIA PRODUCTION PLANT (~95%) NG AS FUEL FOR NPK PRODUCTION PLANTS (~ 5%)

  10. ELFE: THE ENERGY SYSTEM ELECTRICITY (2/3) The Fertilisers Sector is an energy intensive one (ELFE’s electricity consumption ~ 170.000 MWh/yr) 4 turbogenerators installed (~22MW) High Efficiency cogeneration from waste heat (waste heat from exothermal chemical reactions without using fuel) Annual Electrical and Mechanical Secondary Energy Production ~ 750 TJ Annual Thermal Secondary Energy Production ~ 1200 TJ Annual Primary Energy Saving ~ 4000 TJ

  11. ELFE: THE ENERGY SYSTEM THERMAL AND ELECTRICAL ENERGY (3/3) TYPICAL THERMAL AND ELECTRICAL ENERGY BALANCE

  12. ELFE: Basic and On-going Energy Saving Measures (1/3) • Installation of a Cogeneration unit (Thermal and Electrical energy) since 1965 (between the first cogeneration unit in operation) using waste heat from Sulphuric Acid Production Unit. • Progressively, energy saving investments focused on reduction of primary energy use • New ammonia plant installation, using as raw material NG instead of oil, with a very low specific energy consumption (among the 10% of the most efficient plant of the world), including cogeneration unit

  13. ELFE: Basic and On-going Energy Saving Measures (2/3) • The old sulphuric acid plant replaced by a modern one with a higher energy saving efficiency • Installation and operation of 3 additional turbogenerators (saving the 2/3 of electricity used and about 100% of thermal energy used) • Installation and operation of a turboset (machine train) using the off gas and the waste heat from Nitric Acid Production Plant producing significant amount of mechanical energy and saving primary energy

  14. ELFE: Basic and On-going Energy Saving Measures (2/3) • …… (lot of common energy saving investments e.g. recycling condensates from the process, saving steam from blow down water of boilers, installing economizers etc.) • An Energy Management System according to ISO 50001:2011, including all the industrial activities of ELFE’s Complex, will be finalised and certified by an accredited Certification Body, in the near future

  15. ELFE: The high efficiency cogeneration UnitSimplified Diagram (1/4)

  16. ELFE: The high efficiency cogeneration UnitCalculations (2/4) Fc=0, THERMAL EFFICIENCY >>80% Fc=0, ELECTRICAL EFFICIENCY >> 80% Fc=0, PESR=1 PRIMARY ENERGY SAVING = 100%

  17. ELFE: The high efficiency cogeneration UnitThe basic equipment (3/4) The turboset (machine train) G2 turbogenerator

  18. ELFE: The high efficiency cogeneration UnitThe basic equipment (4/4) G1 turbogenerator G3 turbogenerator G4 turbogenerator

  19. ELFE: Legislative difficulties in energy saving • Excise Duty in NG used as Raw Material (must be excluded according to EC Directive) • Extremely high comparative price of NG (above the mean value in Europe) • Excise Duty, RES and taxes applied to the own produced electricity (provision for exclusion according to EC Directive) • High comparative price of electricity from the grid • Absence of State Aid for CO2 cost from indirect emissions (Norway, UK, France, Belgium, Germany etc. have already proceed on)

  20. Conclusions • A. HELLENIC FERTILIZERS AND CHEMICALS ELFE S.A. is the last Greekfertilisersproducerwhich • investes in energysavingsince the beggining of itsoperation • applies the Best Available Techniques in energysaving • Although ELFE achievesvery attractive energy performance indicators, the companysuffersfrom Excise Duties, RES and Taxes in energy due to the governmentallegislation • The European countries recognising the importance of energyadopted the principles of a commonpolicy for NG and electricity and appliedmeasures for supporting the industrialsector. Relatively masures have to beadopted by the Greekgovernment in the framework of Europeancompetitionrules.

  21. THANK YOU ELFE is not only an industrial complex ….. … following BAT and producing energy from waste heat … … ELFE is the only Greek fertilizers Company, producing and exporting high quality competitive products.

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