THE FOLLOWING DIAGRAMS SHOW THE ERK DESIGN OF A THERMAL OIL HEATER THAT HAS ALREADY BEEN IN USE FOR 20 YEARS

DGA IS A LONG STANDING LICENSEE OF ERK AND OFFER THE FOLLOWING VIA FRASER ENERGY :-

• A 11 MWth BIOMASS FIRED THERMAL OIL HEATER WITH AUTOMATIC GAS IGNITION

• DESIGNED AND BUILT TO ASME 1 CODE. NOTE LOW PRESSURE DESIGN @ 5 BARG

• DESIGNED FOR THERMINOL 66 SYNTHETIC OIL

• BIOMASS FIRING IS BY WATER COOLED VEE GRATE, WITH FUEL SPREADER STOKER, ASH DISCHARGE TO WET ASHCONVEYOR . WATER COOLING TO BE INTEGRATED WITH STEAM GENERATOR.( NOT WORKED OUT YET)

• PROPANE GAS IGNITOR FOR AUTO IGNITION. IGNITOR FROM UK MANUFACTURER

• ~20 MINUTES FUEL STORAGE IN HOPPER ABOVE GRATE

• ‘ECONOMISER’ AND AIR HEATER TO PRODUCE ~ 83- 85% EFFICIENCY ON A NET BASIS DEPENDENT ON FIRING CONDITION

• BAG FILTER SYSTEM WITH TWIN FILTERS EACH CAPABLE OF OPERATING WITH THE OTHER ISOLATED FOR PART LOAD.

• NORMAL STACK ARRANGEMENT SHOWN, OTHER OPTIONS AVAILABLE

THERMAL OIL HEATER

BIOMASS FUEL HOPPER

AIR HEATER

CYCLONETWIN

VEE GRATE

WET ASH

TYPICAL ELEVATION OF THE 11 MW HOT OIL HEATER (ERK DESIGN) SK 01

BAG FILTERSTWIN

ASH BIN

TYPICALELEVATION OF THE THERMAL OIL HEATER SHOWING ACCESS ETC SK 02

Arrangement can be adjustedTo suit the site conditions.

TYPICAL PLAN VIEW OF THE THERMAL OIL HEATER SHOWING ACCESS AND ASH HANDLING

SK 03

BIOMASS FIREDOIL HEATER

AIR HEATER&

ECONOMISER

CY

CL

ON

ES

BAGFILTERS

ASHCONTAINER

STACK

ID FAN

SA FANPA FAN

Oil in

Oil out

Oil in‘One Pipe’ ‘One Pipe’

Heat extraction pipes 60.3 OD x 3.6 thk.Manifolds segregated by slide in baffle plate.This diagram shows each pipe with 14 verticalPasses but the number of passes and the tubeDiameter are set by ERK according to thegeometry of the heater..Monitor flow on all discharge pipes (~14 off separate flows)

SK 4BACK TO ERK DESIGN

TYPICAL DIAGRAM

OIL HEATER 11 MW

Eco 1

MainHeater

STEAMBOILER

OIL RECIRC PUMPSWITH FILTERS

M

3 – 24 KG/S PUMPS

2 X 5 KG/S PUMPSTHERMALOIL TANK

EXCLUDED

STEAM5050 KG/H@ 7 BARG

TWIN THERMAL OIL CIRCUIT SHOWING CONNECTION BETWEEN HEATER, STEAM GENERATOR AND ORC

SK 05

COMBNSYSTEM

BAGFILTERS

240 - 310 C

FG AIRHEATER*

<210C

66 KG/S – 1.8 MWE37.7 KG/S – 1.4 MWE

SOLID FUEL

SA (& FGR)

PA

ID

FIRING CONDITIONS

18 CHP Conditions at heaterinlet & outlet terminationpoints

Flowratekg/s

Supplytemp

0c

returntemp

0c

Normal operation –ORC~1400 kWe with steam

37.7 310 210

Steam production only 37.7 240 210

Restricted power production~1400kWe only (no steam)

37.7 310 236

Maximum power only~1800kWe (no steam)

60 310 250

~ 230 C

205 C

230 – 250 C

2.8-3.5 kg/s

37.7 – 60 kg/s

TO ORC POWERPLANT

130 C230-250C

DP

DP

M

OIL FLOWCONTROL

MINOR CCT

MAJOR CCT

A B C D E F G

1

2

3

Control Room and SwitchroomFully assembled in works beforeshipping

Ladder frame dischargerOn Live Fuel store24 hr fuel capacityNot included

SKETCH PLAN OF PLANT THERMAL HEATER FITTED TO AVAILABLE SPACE

SK 06Rev 1

Co

ntro

lR

oo

m

SK 07

DGA Combustion Grate

Tx Thermal oilInlet

~ 230 C

Thermal oilOutlet

~ 250 – 310 C

Water cooledcircuit

P

Tx

T

INDEPENDENT PIPE FURNACE (ERK LICENCE)

NoteThe Haz’ops people believe that the gratecannot be cooled by thermal oil primarilyas the connections to the grate are byflexible hoses.Comment on this proposition are invited asoil burners on most utility boilers use flexiblehoses for hot fuel oil

P

Tx

T

P

Tx

T

P

Tx

T

P

Tx

T

Tx

T

AIR HEATERECO 2

Temp gg

Press gg

T/C in pkt

Commissioningorifice

RETURNS FROMOTHER PANELS

TO OTHERPANELS

FLUE GAS FROMHEATER @ ~360 C

TO BAG FILTERS@ 205 C

P

T

15 independent flow lines

FRONT ELEVATION OF PLANT IN BUILDINGAPPROXIMATE

7

Stack 25 m height5 metre above building

ASH BIN

SK 08Rev 1

ERKA number of pipes manifolded together

So blockage in 1 pipe not easily detected

DGA/UNIQUIPMODIFIED

PROPOSED ALTERNATIVE ARRANGEMENT API COMPATIBLESK 09

API USE A SINGLEPIPE DESIGN AS ABOVE

Tx Thermal oilInlet

~ 120 – 215 C

DGA Combustion Grate

DGA THERMAL OIL HEATER (ERK LICENCE)

Backwall

Thermal oilOutlet

~ 250 – 310 C

ECO 1

ECO 3

SK 10

Water cooledcircuit

P

Tx

DP

T

P

Tx

T

THREE PIPE FURNACE

For 3 and 4 pipe systemsAssume the appropriatelines are provided withsame interlocks and gauges

Tx

DP DP

P

Tx

T

NoteThe Haz’ops people believe that the grateCannot be cooled by thermal oil primarilyAs the connections to he grate are byFlexible hoses.Comment on this proposition are invited asOil burners on most utility boilers use flexibleHoses for hot fuel oil

Tx Thermal oilInlet

~ 120 – 215 C

DGA Combustion Grate

Thermal oilOutlet

~ 250 – 310 C

Water cooledcircuit

P

Tx

T

SIX PIPE FURNACE (ERK LICENCE)

NoteThe Haz’ops people believe that the grateCannot be cooled by thermal oil primarilyAs the connections to the grate are byFlexible hoses.Comment on this proposition are invited asOil burners on most utility boilers use flexibleHoses for hot fuel oil

P

Tx

T

P

Tx

T

P

Tx

T

P

Tx

T

P

Tx

T ECO 1ECO 2

SK 9.1

Temp gg

Press gg

T/C in pkt

Commissioningorifice

T

T

T

TT

T

SK 10UNIQUIP API STYLE DESIGN

This style recommended by Uniquipas meets best practice in oil/gas industry.Oil passes through 6 parallel pipes through‘economiser’ then fired heater

Heat flux increase in Eco by plate welded totubes similar Greens Economiser

Oil temperature continuously monitoredby thermocouple In pockets. No flow measure

If heat flux in Eco too high, fins not installeduntil temperature lower

Membrane wall has been adopted, pendingstrength calculations

From Eco 1

SPREADER STOKER INSTALLATION

SA NOZZLES AND MINOR PENETRATIONS

FURNACE DETAILSACCESS TO THE FURNACE ISBY WITHDRAWING THE GRATE

SK10.1

SIX PIPE DESIGN

SK 11FIRED THERMAL OIL HEATER BY BIOMASS ON VEE GRATE

PLAN OF PLANT THERMAL HEATER

A B C D E F G

1

2

3

Control Room and SwitchroomFully assembled in works beforeshipping

Ladder frame dischargerOn Live Fuel store24 hr fuel capacitysat steam boiler only

SK 06

Thermal oilInlet

~ 120 – 215 CDGA Combustion Grate

DGA THERMAL OIL HEATER (ERK LICENCE)

Sidewall

Sidewall

Sidewall

Sidewall

Sidewall

Frontwall

Backwall

Intwall

Thermal oilOutlet

~ 250 – 310 C

FURNACE ENCLOSURE

ECO 1

ECO 3

SK 04

Water cooledcircuit