Gas Turbines Breathe new life
For Several Paper Companies in Italy

Paper Factories Improve Gas Turbine Efficiency by Improving Filter Lifetime by 200% and Increasing Power Output by 1300 MWh Per Year

Camfil helps customer increase power output with a lower carbon intensity

Several paper companies manage cogeneration factories where they operate 44MW gas turbines with high availability requirements (8500 hours/year).In an effort to increase the performance of the gas turbines, Camfil Power Systems was asked to optimize the existing filtration system for three paper factories. The aim of the collaboration was to decrease the total filtration system dP (pressure drop) to achieve the following:

  • More power output for the same fuel consumption
  • Extended filter lifetime
  • Less time and effort required for filter replacement
  • Higher engine protection and availability

THE SITE

The sites are located in coastal to land-based conditions,where air quality can be challenging. Relative humidity is moderate to high with an average of 73%, and Camfil‘s Air Analysis team estimated 45μg/m3 PM10 dust concentrations. This is 77% higher than there commended annual WHO standard.

ORIGINAL FILTER CONFIGURATION

The original installations have a 2 stage system design consisting of pleated prefilters with G4 efficiency, and final filters with F8
efficiency.
This system presents the following drawbacks:
• High dP spikes, especially in high humidity, rain, or fog conditions result in:
• Prefilter replacement every 4 months,
• Final filter replacement every year.
• Low filtration efficiency and no drainage capabilities cause engine degradation.
• Rigid design limits the choice of products for replacement.

CAMFIL SOLUTION

Camfil conducted several site surveys to recommend the optimal air filter solution to enhance the performance of the engines. The shortest possible installation time during scheduled maintenance was a fundamental prerequisite.

Based on environmental and operational conditions, the OEM and customer decided to upgrade the existing system to a 2-stage static filter solution. The system consists of two air tight filter banks holding the CamFlo Hybrid F7 bag prefilters and the CamGT 3V-600 E10 final filters.

Pre-filter F7

Final Filter E10

THIS SYSTEM HAS THE FOLLOWING ADVANTAGES:

  • Low and stable dP, even under wet and humid conditions:
    - prefilter life time expectation > 1 year
    - final filter EPA Class life time expectation > 3 years
  • Greater engine protection due to EPA efficiency and efficient water drainage
  • Flexible design

PERFORMANCE

The graph below compares typical pressure drop performance of the previous installation and the Camfil solution. Before the upgrade, pressure drop averaged 3" w.g. (750 Pa), and multiple shutdowns for pre-filter replacement were required throughout the year.

The Camfil solution, after one year, maintains a low and stable pressure drop at an average of 1.5" w.g. (375 Pa). As a result, pre-filter replacement decreased to once per year during the plant's annual outage.

SAVINGS

The average change in dP between the old and new solution was calculated to be 1.4" w.g. (350 Pa). According to the turbine specifications, an improvement of 1.4" w.g. means an additional 1300 MWh/yr per plant when running base load (8500 hrs).

This solution has produced additional savings for the end user in terms of maintenance and operating costs, as well as superior engine protection and air cleanliness.

Additionally, since pressure drop and efficiency class has improved, fuel consumption has also decreased per megawatt hour produced. This means that the carbon intensity is impacted positively by approximately 2% as a result of filtration.

INCREASE FILTER LIFETIME

  • Prefilter lifetime expectation > 1 year
  • Final filter class lifetime expectation > 3 years

INCREASE POWER OUTPUT

  • Reduce pressure drop by 48%
  • Increase power output by 1300 MWh /Yr

INCREASE AIR INLET QUALITY

  • EPA efficiency decreases engine degradation
results:
  • From 3 to 1 prefilter changes per year
  • Final filter life expectation from 1 to 3 years
  • Gain of 1300 MWh per year with a lower carbon intensity
Julkaistu maanantai 27. huhtikuuta 2020
Camfil Oy
Ruukinmestarintie 11
02330 ESPOO
info.finland(at)camfil.com
etsi yhteyshenkilö