In today's industrial landscape, the demand for efficient heating solutions with lower CO2 emissions is more critical than ever. Many industries are facing the challenge of balancing operational efficiency with reducing their environmental footprint. At Atlas Copco Rental, we understand these challenges and are committed to delivering innovative solutions that meet both performance and sustainability goals.
Introducing hybrid superheated steam solutions
Many industries rely on (superheated) steam for various applications. Traditionally, steam generation has relied on fossil fuel-powered boilers that are efficient but have a significant environmental impact. In contrast, electric boilers provide a cleaner alternative but often face challenges due to their high power requirements.
To address these issues, our experts have developed an innovative hybrid superheated steam solution. This system combines the strengths of both traditional and electric methods, offering a sustainable and efficient setup for steam generation. By integrating a traditional oil or gas-fueled boiler with an electric superheater, we create a flexible and eco-friendly solution that significantly reduces emissions while still meeting high steam demands. This solution ensures that industries can maintain productivity without compromising their environmental commitments.
Two main strategies ...
How did we do this? There are two main strategies. The first option is to replace the fuel-powered superheater with an electric one, completely eliminating CO2 emissions from the superheating process. However, this depends on the amount of electrical power available on-site and the current capabilities of electric superheaters.
The second method, which combines both fuel-fired and electric superheaters, is a more advanced approach designed to address a common challenge in steam systems—wasted saturated steam. This waste usually happens when superheated steam consumption drops below the minimum flow that a fuel-fired superheater needs to function properly. In this setup, an adapted electric superheater steps in to handle the steam when consumption falls below this minimum level. It can cover the range from zero steam demand to the minimum flow required by the fuel-fired superheater, ensuring that superheated steam is delivered even when steam consumption is very low. By using both technologies together, the system ensures continuous superheated steam production, regardless of fluctuations in demand. As a result, not only are CO2 emissions reduced, but the wasted saturated steam that would normally be lost is fully avoided. This significantly improves efficiency and ensures that the steam system is always operating at optimal levels, even during low-demand periods.
The key advantages of electric superheaters
- Electric superheaters are incredibly energy efficient, turning all the electricity they use into heat with minimal loss.
- These electrical superheaters also have a faster startup time and a very high turndown ratio.
- Additionally, they provide precise temperature control, which helps to optimize process conditions and improve product quality.
- Hybrid superheated steam solutions offer a versatile and efficient way to generate steam while reducing CO2 emissions.
Why superheated steam?
Superheated steam plays a crucial role in various industrial applications, where its unique properties offer significant advantages over saturated steam.
1. Ensuring reliable performance in turbines and engines
In industries where turbines, turbo alternators, or turbopumps are critical components, the quality of steam can directly impact performance. Superheated steam is often required to prevent condensation within these machines which could cause mechanical damage or reduce efficiency. For example, Atlas Copco Rental recently supported the Naval Group during a submarine repair project in Toulon where 100% steam quality was mandatory. To meet this requirement an electrical superheater was employed to ensure that only superheated steam was used safeguarding the reliability of the turbines.
2. Overcoming limitations in steam set ups
Superheated steam is also essential in facilities where existing steam networks have not been designed to handle saturated steam efficiently. This is especially true in operations where the stationary boiler on-site is a water tube boiler that produces superheated steam. If the network lacks sufficient steam traps, using saturated steam could lead to inefficiencies as excess condensates may not be properly captured. Atlas Copco Rental has supported clients like GIE Osiris in France by delivering the first temporary hybrid superheated steam solution. This approach significantly reduces steam dissipation even during periods of low steam consumption, resulting in cost savings and optimized energy use.
3. Process-specific requirements
Many industrial processes demand superheated steam for precise temperature control and enhanced energy transfer. Unlike saturated steam, which condenses at a fixed temperature, superheated steam can continue to transfer energy without phase change. This makes it ideal for applications that require high and consistent temperatures. Whether it's for catalysis/ chemical reaction processing, cleaning, curing, or surface drying and nanotechnologies, superheated steam is often the only viable option to meet stringent process requirements.
At Atlas Copco Rental, we are dedicated to providing innovative and sustainable solutions to meet temporary steam requirements. We are actively advancing towards fully electric solutions for the future of industrial steam generation. Our next challenge is developing hybrid boilers capable of generating saturated steam to meet the diverse industrial needs.
