We interviewed with Fatih Savaşkan, General Manager of Jenesis. We believe that you will enjoy reading our next chapter about said technologies with the Mechanical Engineer Mr. Savaşkan.
While underlining details and specifics of the system that they have developed, Mr. Savaşkan shared the following, ’’We can achieve %99 per cent efficiency thanks to our highly heated transfer surface areas, low radiation loss, low NOx burners in Class III combustion, special thermo-block interior design and alternatively applied condensing or non-condensing flue gas economizers.’’
Fire/smoke tube boilers are capable of creating steam at the desired pressure level in approximately 45-90 minutes. However, producing steam at the desired pressure levels could take only 3-5 minutes with Jenesis HUB system. If this is the case, it will be possible to reduce the cost of fuel consumption to reach desired pressure levels that could take otherwise 45-90 minutes that requires burner to work at full capacity. In general, for a textile mill that is operational in a year, savings are achievable at desired levels for 5t/h steam producing without spending extra 200,000 TL worth of steam.’’ Mr. Fatih Savaşkan continued his wording as follows, ‘’Fire/smoke tube boiler, which works at full capacity, could lose its efficiency if it has to operate in lower capacities because the level of efficiency in this case will leave catalog value and will experience significant losses. However, small modules that make up for the HUB system are to be completely deactivated when they are not in need of and the desired level of module remain active and working commitments at highest efficiency are to be assured constantly.’’
Quick Response at Peak Drafts
While pointing out the advantages provided with Jenesis HUB system that they have developed, Savaşkan shared the following, ‘’In Jenesis HUB System, immediate action made possible at peak drafts. Fire/Smoke tube boilers response rates are lower at peak drafts as it contradicts with common belief. While fire tube boilers’ volume of the steam drum capacity and pressure are variant elements, for each 1000 kg/h capacity only about 2-3 kg of steam is stocked. For example, in the steam dome of a boiler that has the capacity of 10 t/h, stock ranges in between 20-30 kg at peak steam said support may last for only 10-15 seconds as approximate.
On the contrary, since the water stock volume in the scotch type boiler is high, there is a peak draft and when the pressure drops, it takes a long time to heat all of this stock water in the boiler and produce steam. However, in Turboblok in Jenesis HUB system with internal structure as water levels are at minimal levels, rapid response made possible at peak steam drafts. While in fire tube boilers pressure drop may cause while the pressure of the set pressure can be reached again, it takes about 10-15 minutes, in Jenesis HUB system same process experienced in only a minute to reach set pressure again.’’
Constant Quality and Dry Steam
Jenesis General Manager Fatih Savaşkan said, ‘’Due to the fact that in Jenesis HUB system both automation and temperature and pressure can be controlled at desired levels simultaneously and constantly, dry steam can be produced constantly and with quality. Dry and high quality steam must be sent to the steam turbines fed by the water tube boilers used in power plants. If not, turbine blades rotating at high speed will experience damage in short period of time that would cause millions of dollars damage. With the application of the same technology, necessary equipment, skillset, knowledge, expertise and available automation at our production as of our standards, we can produce steam whenever we want at the desired amount, dry and quality and also we can internalize even superheated steam to our processes.
As in water tube boilers there is not sufficient level of water pressure and since Turboblock interior design makes it possible to placing more heat exchange surfaces in lower volumes, savings can be achieved in space. Also, as modular system design that can be placed next to one another and the pumps and panels that are placed on the body parts, the boiler room is made smaller.’’
Easy Mills Uninterrupted for 72 Hours
While giving detailed information on the scotch type boilers, Savaşkan, ‘’Because of high stock water levels in hot and conditioned boiler water produced by blow-down from the surface and bottom in scotch type boilers is rising constantly. As we cannot talk about stock water in in water tube boilers, there is no need to buffle. Only with the removal of condense highly conductive that integrates into the system and decomposes under the separator, system conductivity values can be kept under control. Also, as in water pipe designs control over water levels are not matters of concern, proportional level control system and continuous water level monitoring are also out of topic. Thus, as cost pressure on using automatic blow-down systems as in scotch boilers is not a must-follow step, by it also eliminates the need to constantly monitor conductivity and water level status by competent earners.’’
‘’Automation system that has been developed made possible the feed water pump and the burner to be operated in synchronization and proportionally each other. Smart fault detection system are attached to the system that is capable of identifying location of issues by itself with the information received from many sensors on the system, fuel meter and steam meter that you placed into your system provides information that can be monitored by PLC Scada system instantly with its efficient systematic touch screen feature. Anything can be recorded and can be transferred to central automation or USB flash disc and further ethernet connection allows remote access to the system.
Basic simple design and equipment that have proven themselves in excesses of hundred facilities in years that minimize maintenance and repair costs. Factory or mill stoppages are unnecessary for maintenance and repair work that does not have a spare boiler. Thanks to the modular HUB system, the factory can operate with other modules while single module is being disabled and maintained. Turboblok interior design allows pipe changes that can be made in just a few hours with the cartridge system. Time savings and damage free work made possible as time consideration associates with changing individual pipes in fire and smoke tube boilers is apparent and as damage consideration associates with renewing boiler mirrors eliminated by the cartridge system.’’
Automation solves issues that are occurring frequently by analyzing data stored and with the preventive maintenance issues can be solved and downtimes can be minimized. Further, 3-parameter control system placed onto the system helps monitoring swarf layer that may occur in the heat transfer pipes. In this way, when swarf layer comes out, system intervene in and alert user to have precaution over and also guide the technician to solve the problem. This makes it possible to enhance efficiency. In addition, pump cooling and protection systems have been developed for cavitation caused by hot condensate, which is the biggest problem of feed water pumps. Thanks to these systems, the life of feed water pumps is extended and frequent breakdowns or replacements are prevented. Thanks to these features, the continuity of high efficiency and trouble-free operation can be ensured for many years. Thanks to the periodic maintenance service that can be obtained from the Jenesis authorized and expert service department, the system can be fixed before any further issue may be reported.
Possibility to Generate Free Electricity
While giving more information about the advantages offered with the system, Savaşkan said the following, ’’One of the biggest advantages of Jenesis HUB System is that with the minimal changes in investment cost is that it can be designed to higher pressure. In this way, generating electricity through from a high pressure saturated steam turbine made possible. Adding, steam pressure at the exit of saturated steam turbines can be adapted to the required pressure level automatically. Thus, by only increasing operational fuel costs only by % 1-2, high pressure steam is made possible and it is possible to pull up the steam pressure from high pressure to 6-7 barg in steam turbine to generate electricty with these savings.
Since this technology, which dates back to more than 50-60 years and is widely available in countries, is very costly, whose investment payback period was around 8-10 years in Turkey. Therefore, it has never been appreciated or favored as a system in our country. However, Jenesis can now generate nearly 100-130 kW of electricity in a facility that consumes an average of 5 t/h steam by coupling the saturated steam turbines produced in our country with the Jenesis HUB system. Thanks to this system, keeping amortization periods in between 3-4 years, our industrialists can both produce at lower costs and can now reduce their carbon footprint.’’
