Steam turbine installation for electricity generation – energy loss recovery in industrial processes

Instead of wasting energy on steam parameter reduction in a cooling station, the chemical plant used it to produce its own electricity. The installation of a steam turbine with a synchronous generator made it possible to utilize over 87 GWh annually and significantly reduce electricity purchase costs from the grid.

The challenge

In many industrial plants, including the chemical industry, steam boilers are used for process purposes. Steam exiting the boiler has high pressure and temperature parameters, which are then reduced to the level required by technological installations – usually in pressure-reducing and cooling stations. This mode of operation means that a significant portion of the primary energy is irretrievably lost instead of being used in the process of energy production.

In the analyzed plant, the challenge was to find a solution that would allow the energy lost during steam parameter reduction to be utilized while simultaneously reducing electricity purchase costs from the grid.

Our approach

Already during the preliminary analysis, we noticed that the plant was losing a huge energy potential during process steam reduction in the cooling station. Therefore, we proposed an alternative in the form of a steam turbine with a synchronous generator, which enables energy recovery from steam expansion.

We conducted detailed measurements of boiler and pressure-reducing and cooling station parameters, and then prepared a complete project concept along with a profitability analysis. A key element was matching the turbine to the plant’s variable demand profile and ensuring that the generated electricity would be fully utilized for production process needs.

DB Energy engineers' approach to project implementation

Solution

DB Energy proposed replacing the pressure-reducing and cooling station with a steam turbine system coupled with a synchronous generator. As a result, the steam expansion process – previously causing losses – was transformed into a source of electricity generation. The turbo set produces energy directly used for the plant's own needs, which additionally reduces transmission losses and improves the overall energy balance of the facility.

During the preparatory stage, DB Energy conducted measurements and energy balance calculations, confirming the potential for energy recovery. Next, a complete modernization project concept was developed, including turbine and generator selection and integration with the existing steam infrastructure.

Results

The investment implementation brought significant energy and financial benefits:

reduction of energy losses resulting from steam expansion,
electricity generation for the plant's own needs,
improved fuel efficiency in the steam boiler,
reduced electricity purchase costs from the grid.

Overall, the investment allowed savings of over 87 GWh annually, with a payback period of approximately 4.5 years.

results - modernization - efficiency — Energy and financial benefits

Conclusions

The installation of a steam turbine with a synchronous generator is an example of a solution that allows existing energy processes in a plant to be used for additional electricity production. Instead of irreversibly losing energy in the pressure-reducing and cooling station, the plant gains a real source of savings and improves energy security through partial independence from external electricity suppliers.

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