Εκτίμηση εναλλακτικών ενεργειακών έργων στον τομέα της βιομηχανίας. Εξέταση έργου εγκατάστασης μονάδας Συμπαραγωγής για την κάλυψη θερμικών και ηλεκτρικών αναγκών των εγκαταστάσεων της ΕΛΒΑΛ-ΧΑΛΚΟΡ Οινοφύτων

Evaluation of alternative energy projects in the industrial field. Assessment of the project of installation of a CHP unit for the coverage of the electrical and thermal needs of ELVAL-HALCOR company in the Oinofyta facilities. (Αγγλική)

  1. MSc thesis
  2. Drakotos, Athanasios
  3. Διοίκηση Επιχειρήσεων (MBA)
  4. 10 Σεπτεμβρίου 2022 [2022-09-10]
  5. Αγγλικά
  6. 121
  7. Stefanou, Konstantinos
  8. Stefanou, Konstantinos | Ballas, Apostolos
  9. ELVALHALCOR, CHP-CHPHE, Natural gas, Gas turbine, Steam turbine, Photovoltaics, Motor Efficiency
  10. 35
  11. 42
  12. Figure 1 1 - Spatial boundaries of a CHP unit [1] 13 Figure 1 2 Definition of the spatial boundaries of a cogeneration unit in case of presence of secondary steam turbines [1] 15 Figure 1 3 Spatial limits of a cogeneration unit with motors connected in series [1] 15 Figure 1 4 Cogeneration-non cogeneration power generation parts [1] 16 Figure 1 5 System with additional combustion used for cogeneration and for heat derivatives only [1] 17 Figure 1 6 Reference prices for CHP-renewable sources [2] 20 Figure 1 7 Correction factors [2] 21 Figure 2 1 China’s demand for gas (2010-2020) [3] 22 Figure 2 2 S dry natural gas production 2000-2050 [4] 23 Figure 2 3 Trend line of gas prices for non-household consumers [5] 24 Figure 2 4 Gas pipeline routes in south east Europe [5] 25 Figure 2 5 Cost of natural gas in the EU map [6] 25 Figure 2 6 Average value of imported NG chart [7] 26 Figure 2 7 Average value of imported NG chart [8] 26 Figure 2 8 Average value of imported NG chart [9] 27 Figure 2 9 Average value of imported NG chart [10] 27 Figure 2 10 Average value of imported NG chart [11] 28 Figure 2 11 Average value of NG chart [12] 28 Figure 2 12 Price of imported NG in Greece 29 Figure 2 13 Trend line of cost of NG for ELVAL for the last 10 years 29 Figure 2 14 Erratic estimation of cost of NG based on previous data 30 Figure 2 15 Long term natural gas price [13] 30 Figure 2 16 Cost of electrical power map [16] 32 Figure 2 17 Trend line of cost of electrical power for ELVAL for the last 10 years 34 Figure 2 18 Comparison of trendline of cost of electrical power for ELVAL and grid for the last 10 years 34 Figure 2 19 20 year estimation of Cost of electrical power 35 Figure 2 20 Auction price of CO2 (€/tn) 37 Figure 2 21 Auction volume of CO2 (ton) 37 Figure 2 22 Price forecast of CO2 for the next 20 years 38 Figure 2 23 Volume forecast of CO2 for the next 20 years 38 Figure 2 24 Price forecast of CO2 for the next 10 years [28] 39 Figure 2 25 Production of CO2 (kg/MWh) according to plant efficiency 41 Figure 2 26 Price of electrical power for Photovoltaics [32] 42 Figure 2 27 Price of electrical power for Photovoltaics [33] 43 Figure 2 28 Price of electrical power for Photovoltaics [34] 44 Figure 2 29 Cost of electrical power form renewable sources [35] 44 Figure 2 30 Readjustment of solar power price 45 Figure 2 31 Electrical market marginal price or Spot Price [36] 46 Figure 2 32 Trend line of electrical market marginal price or Spot Price 47 Figure 2 33 Weighted average price of electrical power for 2014 [38] 47 Figure 2 34 Weighted average price of electrical power for 2015 [39] 48 Figure 2 35 Weighted average price of electrical power for 2016 [40] 48 Figure 2 36 Weighted average price of electrical power for 2017 [41] 48 Figure 2 37 Weighted average price of electrical power for 2018 [42] 49 Figure 2 38 Weighted average price of electrical power for 2019 [43] 49 Figure 2 39 Weighted average price of electrical power for 2020 [44] 49 Figure 2 40 Weighted average price of electrical power for 2021 [45] 50 Figure 2 41 Weighted average price of electrical power for 2022 [46] 50 Figure 2 42 Weighted average price of electrical power (2014-2022) 51 Figure 3 1 ELVAL Casting Line Melting Furnace 53 Figure 3 2 ELVAL Hot Rolling Heating furnace 54 Figure 3 3 Line casting strips of aluminum based bearing alloys [47] 55 Figure 3 4 Symetal annealing furnace 55 Figure 3 5 ELVAL consumption of NG per month (MWh) 56 Figure 3 6 ELVAL electrical consumption per month (MWh) 56 Figure 3 7 ELVAL estimation of consumption of gas until 2027 per month (MWh) 57 Figure 3 8 ELVAL estimation of electrical consumption until 2027 per month (MWh) 58 Figure 4 1 Gas turbine and compressor rotor with combustion chamber [48] 60 Figure 4 2 Diagram of an open cycle Gas Turbine [49] 61 Figure 4 3 Diagram with closed cycle gas turbine [50] 61 Figure 4 4 STF A100 (GRT/HRT) non-reheat steam turbine [51] 62 Figure 4 5 Back pressure and condensing turbine [52] 62 Figure 4 6 Steam power plant cycle [53] 63 Figure 4 7 Forced draft cooling tower [54] 64 Figure 4 8 Combined Cycle [55] 65 Figure 4 9 Cogeneration heat and power plant [57] 66 Figure 4 10 ELVAL aerial view 67 Figure 4 11 Gas turbine without heat recovery 68 Figure 4 12 Table of characteristics of different GTs 69 Figure 4 13 Aerial view of new heating furnaces of Hot Rolling 70 Figure 4 14 Gas turbine with heat recovery to steam turbine 71 Figure 4 15 Steam turbine without installation of gas turbine 73 Figure 4 16 Aerial view of the installed furnaces of ELVAL 74 Figure 4 17 Aerial view of the installed furnaces plus expected ones of ELVAL 75 Figure 4 18 Photovoltaic installation on rooftops [62] 78 Figure 4 19 Motor’s life cycle costs 80 Figure 4 20 Comparison of efficiencies of different types of motors [63] 81 Figure 4 21 Comparison of efficiencies of AC IE4 to DC motor 82 Figure 4 22 Duty cycle of ELVAL’s Hot Rolling Mill main motors 83 Figure 5 1 Greece’s inflation rate [64] 86 Figure 5 2 Scenarios of prices of electrical energy (€/MWh) 88 Figure 5 3 Αverage construction cost of combustion turbines [68], [69] 89 Figure 5 4 Average construction cost of units [68], [69] 90 Figure 5 5 Average natural gas combined cycle power plant construction cost [68], [69] 90 Figure 5 6, Average construction cost of units [68], [69] 91 Figure 5 7 O&M costs for 5-MW Simple cycle plant-aeroderivative gas turbine [65] 92 Figure 5 8 Steam turbine capital and O&M costs [70] 93 Figure 5 9 O&M costs for 300-MW Simple cycle plant gas turbine [65] 94 Figure 5 10 Scenarios of evolution of Natural gas price 2022-2045 97 Figure 5 11 Scenarios of evolution of CO2 price 2022-2045 97 Table 2 1 CO2 emissions from various fuels in relation to the primary energy content [29] 40 Table 2 2 CO2 emissions of various fuels in relation to 1 MWh,e in relation to averaged power plant efficiency [29] 40 Table 3 1 Averaged MW consumption of ELVAL per year 58 Table 4 1 Available surfaces for installation of PVs on rooftops of ELVAL 78 Table 4 2 Data of ELVAL’s DC motors examined for replacement 85 Table 5 1 Data of ELVAL’s WACC from yearly financial reports 85 Table 5 2 Coefficients of tn CO2/NM3 of natural gas 87 Table 5 3 Parameters for calculation of average yearly production of PVs 101 Table 5 4 Motors examined for replacement in ELVAL 102 Table 6 1 MWh price payed according to price of NG and CO2 costs 103 Table 6 2 Calculation of MWh produced by 2 GTs 103 Table 6 3 CO2 cost calculation 104 Table 6 4 Maintenance cost calculation of Gas Turbines 104 Table 6 5 Maintenance cost calculation of Steam Turbines 105 Table 6 6 Operation cost calculation of GT-ST turbines 105 Table 6 7 Expenditures calculations for Gas Turbines 106 Table 6 8 Expenditures calculations for Steam Turbines 106 Table 6 9 Depreciation calculation 106 Table 6 10 Depreciation calculation of PV-Steam turbine project 106 Table 6 11 Net Cash Flow Calculation 107 Table 7 1 NPV calculation for 2GTs projects 108 Table 7 2 NPV calculation for 2GTs - 1ST project 109 Table 7 3 NPV calculation for 1GT - 1ST project 110 Table 7 4 NPV-ARR-PB-PI-IRR for ST project 110 Table 7 5 NPV-ARR-PB-PI-IRR for Photovoltaic project on rooftops 111 Table 7 6 NPV-ARR-PB-PI-IRR for Photovoltaic project on rooftops and ground 111 Table 7 7 NPV-ARR-PB-PI-IRR for Photovoltaic project on rooftops and Steam Turbine 111 Table 7 8 NPV-ARR-PB-PI-IRR for replacement of all motors project 112 Table 7 9 NPV-ARR-PB-PI-IRR for replacement of five selected motors project 112 Table 8 1 Comparison of viable projects 113
    • Σκοπός της διατριβής είναι να προσδιορίσει εάν το επενδυτικό έργο εγκατάστασης μονάδας συμπαραγωγής θερμότητας και ηλεκτρικής ενέργειας (ΣΗΘ) κατάλληλου μεγέθους αποδειχθεί οικονομικά επωφελές για την εταιρεία ΕΛΒΑΛ-ΧΑΛΚΟΡ. Παράγοντες όπως η τιμή του φυσικού αερίου, το κόστος ισχύος, η τιμή της ηλεκτρικής ενέργειας, το κόστος εκπομπών, ο συντελεστής απόδοσης της μονάδας είναι μερικοί από τους παράγοντες υπό εξέταση προκειμένου να αξιολογηθεί όσο το δυνατόν ακριβέστερα η βιωσιμότητα αυτού του έργου. Η ανάλυση έχει διεξαχθεί με υπολογισμό δεικτών όπως ARR, NPV και διενέργεια ανάλυσης ευαισθησίας σε αυτούς. Τέλος, το έργο αυτό έχει συγκριθεί με άλλα μικρότερα ενεργειακά έργα όπως η εγκατάσταση φωτοβολταϊκών συστημάτων ή η αντικατάσταση κινητήρων με πιο αποδοτικούς εντός των εγκαταστάσεων της εταιρίας ΕΛΒΑΛ-ΧΑΛΚΟΡ στα Οινόφυτα.
    • The scope of the dissertation is to determine if the investment project of installation of a cogeneration heat and power unit (CHP) of appropriate size will eventually be economically beneficial for the ELVAL-HALCOR company. Factors like the price of natural gas, power cost, price of electrical power, cost of emissions, coefficient of performance of the unit will be some of the examined factors in order to evaluate as accurately as possible the viability of this project. The analysis will be conducted by calculating indices like ARR, NPV and conducting a sensitivity analysis upon them. Finally, this project will be compared to other smaller energy projects like the energy upgrade of specific furnaces or the installation of PV systems within the ELVAL-HALCOR Oinofyta site, based on the indices calculated for each single project.
  14. Αναφορά Δημιουργού 4.0 Διεθνές