COMPRESSOR TECHNOLOGY REDESIGNED – DEVELOPMENT OF A STEAM TURBOCHARGER
Heat transition is more than a buzzword – it is a necessary response to climate change and the challenges it poses to businesses worldwide. We recognize that the efficient use and delivery of process heat is a key factor in ensuring success. This is especially true for companies that rely on steam-based processes and need to transition to climate-friendly production with technologies that make the transition both environmentally sustainable and economically effective. Heat pump technology plays a key role in today’s requirements for CO2 reduction in steam or high-temperature heat generation. As a turbomachinery specialist, we have made significant progress in the key area of compressor technology.
Turbonik and Fraunhofer UMSICHT in Oberhausen laid the foundation for another efficiency technology from North Rhine-Westphalia with the project “Steam Turbocharger – Efficiency Improvement in Industrial Companies through the Integration of Steam and Compressed Air Networks”. The project was funded by the state of North Rhine-Westphalia. Together, the partners initially developed a conceptual framework and, as the project progressed, the technological details of a steam turbocharger that combines the technologies of high-efficiency micro steam turbines and compressors for compressed air generation. This innovation has the potential to significantly increase the efficiency of industrial processes while minimizing environmental impact, combining environmental sustainability with economic viability.
Integration of turbine and compressor technology
The project successfully developed and built a prototype of this steam turbocharger. But how does the steam turbocharger work? A turbine is set in rotation, for example during steam expansion in an industrial process. In this steam turbocharger technology, the connected turbine shaft directly drives a compressor instead of a generator. As a result, compressed air can be produced directly, without the use of additional electrical energy, in a power range of up to 150 kW. This compressed air can then be used directly in industrial processes, significantly increasing overall efficiency. Both the turbine and the compressor operate at extremely high speeds and the shaft is lubricated with water. This unique system has been used successfully for years in our micro steam turbines.
A particularly exciting aspect of the steam turbocharger is its versatility. Building on this technology platform and design, the compressor technology can be adapted for other gases. Of particular interest is the potential use of hydrogen. Given the growing importance of hydrogen in the energy and transportation sectors, this could offer significant advantages and open up new possibilities for the energy transition.
Saves electricity and CO2
But the steam turbocharger offers more than just technological advances. By using it, operators can save valuable electricity that would otherwise be required to power conventional compressors. Depending on the fuel used for steam generation, each steam turbocharger can save up to 486 tons of CO2 emissions per year. This technology not only combines two efficiency measures, but also aligns companies’ economic and environmental goals with the broader goals of increasing energy efficiency and reducing greenhouse gas emissions. By using this technology, companies can optimize their production processes, reduce their costs, and minimize their environmental impact.
With the introduction of technologies like the steam turbocharger, we are on the right track to successfully managing the climate transition and creating a more sustainable and efficient industrial future. This requires innovation, a willingness to change, and a willingness to go new ways.
Together with Fraunhofer UMSICHT, we have shown that we are ready to face these challenges and provide solutions that are both ecologically and economically sustainable. This project is a prime example of how science and industry can work together to address the major issues of our time. We see this project as an important contribution to climate change mitigation. It shows that sustainable industrial production is not only possible, but also economically efficient. Another step has been taken towards a successful heat transition and a more sustainable future. It is now up to all of us to continue on this path and to fully exploit the opportunities offered by such innovative technologies.
Funding Acknowledgement
The project “Steam Turbocharger – Efficiency Improvement in Industrial Companies through the Integration of Steam and Compressed Air Networks” was funded by the Ministry of Economic Affairs, Innovation, Digitalization, and Energy of the State of North Rhine-Westphalia, with support from the European Regional Development Fund (ERDF).