Turkish Carpet Factory Lays Down CHP Plant: Turkish carpet manufacturer chose MTU for CHP plants in its textile manufacturing facility
Carpets from the Turkish textile manufacturer Saray Hali are in demand throughout the world. Every year around 7.5 million m2 of machine-woven products leave the factory in Kayseri, central Turkey. In order to achieve sustainable increases in manufacturing efficiency, the company decided to introduce combined heat and power (CHP) technology from MTU Onsite Energy. Since April 2011, two CHP plants have been supplying the 500 000 m2 Saray Hali facility in Turkey with electricity and heat for production processes.
The turnkey project is based on Type GR 2145 N5, 50 Hz gas engine systems and covers all the components needed from the 20-cylinder Series 4000 gas engines, the generators and thermal modules through the steam generators to the complete electronics systems including plant control. The entire concept is rounded off by a 10-year maintenance contract covering fault clearance, repair and a major overhaul after 64 000 hours. Customer service will be looked after by the local MTU distributor, MTU Turkey. The company said this means Saray Hali had to deal with just one single contact from the initial planning of the plant right through to the operational stage. MTU said the carpet manufacturer also benefits from the tightly woven on-site service network, which is unique among CHP plant manufacturers in Turkey.
Other key factors in the award of the contract were reliability and consistently high levels of availability, said MTU. In fact, the Kayseri plant is located more than 1000 m above sea level and at that altitude, most other engines would only operate at considerably reduced power. Under those conditions, MTU guarantees an efficiency rate within the 5% tolerance set out by DIN ISO 3046.
For the carpet factory, the continuous power cogeneration plants each produce 2145 kW of electrical power as well as 1210 kW of thermal energy from the engine coolant system and 1150 kW of thermal energy from the exhaust system. And during the process, less than 500 mg/Nm3 of nitrogen oxides and 300 mg/Nm3 of carbon dioxide are produced. These values are significantly lower than conventional compact power plants, and they meet the emissions requirements set out in the German TA Luft specifications, said MTU.
Saray Hali can choose how best to utilize the electricity generated by its natural gas plants. In network parallel mode, at full power, the units produce surplus electricity that can be fed into the public grid in order to generate income. If only enough electricity to meet the factory’s needs is required the modules can be switched to mains backup mode or isolated operation (island mode). The power generated in this way is enough to supply the facility’s most important electrical consumers, and it guarantees Saray Hali independence from the public supply
system if power outages occur.
In addition to electricity, the cogeneration modules also produce cost-effective and reliable thermal energy for production processes. This is achieved by reclaiming heat from the engine coolant and the exhaust gas, which reaches temperatures of several hundred degrees. At Saray Hali, this energy is fed into an in-house steam generator. The steam produced is then used for manufacturing processes. MTU said the combined generation of electricity and heat means the CHP plant achieves an overall efficiency rate of approximately 90% and for Saray Hali, it is an energy-efficient and costeffective system that will begin to reap economic benefits within two years.