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30/11/2011
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E.On's CHP (combined heat and power) site in Stoke-on-Trent is now on track to make energy savings of 51% from its recently uprated compressor installation.
 Compressor manufacturer Mattei installed an AC30sH compressor – the smallest of its 30kW units – as well as efficient dew point-dependant switching devices for two ancillary dryers.
The £40 million CHP plant comprises a gas turbine, heat recovery boiler and steam turbine, together capable of producing 60MW of electricity and 60 tonnes per hour of steam.
Neil Price, performance co-ordinator at E.On, explains that the plant supplies the electricity and steam to a Michelin tyre factory – which shares the site – on a 24-hour basis, with the steam being used in its manufacturing processes.
To ensure Michelin Tyre has complete security of supply, the plant has three standby boilers, which can each produce 20 tonnes of steam per hour, and the local grid provides back-up electricity. Additionally, the boilers are capable of using fuel distillate as well as gas.
Mattei compressors have been operating at the site for almost 10 years, supplying instrument air to both the gas and steam turbines.
However, when Mattei carried out its data logging exercise, it found that replacing one of the two existing Mattei AC2030H compressors with a more energy efficient AC30sH compressor would make a substantial difference.
As well as installing the new equipment, it was necessary to make modifications to the steel container, including improvements to access, ducting and pipework.
Price also observes that Mattei had a short window of opportunity to complete the works, while the turbines were undergoing scheduled maintenance.
"The utilisation of CHP – a microgeneration technology that increases efficiency and reduces carbon emissions – means we run a very efficient operation at Stoke-on-Trent," comments Price.
"Therefore, we welcomed Mattei's review of our compressed air system, and the fact we've been able to improve its efficiency by around 50%... Mattei has also demonstrated that its team is capable of working within very tight parameters, in terms of timescales, health and safety procedures and access."
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Author
Brian Tinham
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