22 May 2012

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Capacity cooler

An existing high pressure gas cooler from a foreign supplier seems to have 50% less thermal capacity than expected. After a discussion with the client about the possible problems, we simulate the cooler in Computational Fluid Dynamics (CFD). Our aim is to determine a modification range for the cooler. We are faced with a construction for high pressure hydrogen service which is fully welded together. The client would like confirmation in advance that a possible modification will lead to the desired results. It is an expensive and time-consuming task to dismantle the shell, so we make use of a 'service stop'. A erroneous distribution and bypass of flows on the shell side appear to have a strong influence on the capacity. In consultation with the client, we simulated (CFD) several design variations which demonstrates the exact cause of the problem. It emerges that the end baffle causes 10% of the flow to be bypassed. This has an enormous impact on the “logarithmic temperature difference”, the driving force behind the exchange of heat. The CFD pattern shows that the flow speed at the end of the bundle is nearly zero (zero heat exchange capacity) whilst the surrounding flow is exceptionally strong.

E.ON Gas storage

Bronswerk^® Heat Transfer receives an order from E.ON Gas storage in Germany (formerly Ruhrgas) to supply three double, high pressure natural gas coolers (up to 230 bars). They will be used in the natural gas underground storage process; a reserve for when the demand is high, such as in winter time. The coolers are part of an existing natural gas installation for which we have already supplied natural gas coolers. They have been operational for many years to the complete satisfaction of E.ON. The new, three double natural gas coolers cool the gas in two steps fed from three compressors. Cooling with outside air takes place after every stage. As the underground gas storage is located in a rural environment, strict noise regulations apply for the coolers. We therefore supply the cooling fans with a special low noise execution finish. Much attention is given to the reduction of energy consumption, resulting in highly efficient coolers that are fully assembled and tested.

E.ON Energy from waste

In 2009, Bronswerk^® Heat Transfer supplies a steam condenser to E.ON Energy from Waste. This condenser is part of a waste incinerator for sorted industrial and household waste situated on Oosterhorn industrial area in Delfzijl, near Groningen. Bronswerk^® supplies the steam condenser and the skid, that is required to convert and process steam into condensate; including steam tube, condensate pumps, condensate control valve and vacuum unit. Bronswerk® is involved from beginning to end: from the process design to the assembly on-site and start-up. A close cooperation with E.ON and other parties is maintained throughout the entire process in order to provide a smooth operation of all activities. In 2010, the waste incinerator will successfully start operating.

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