Foster Wheeler Energia Oy P.O.BOX 201, FI Varkaus, Finland

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1 INITIAL OPERATING EXPERIENCES OF THE 135 MWe KLADNO LIGNITE FIRED POWER PLANT Riku Parkkonen, Kalle Nuortimo, Timo Jäntti Foster Wheeler Energia Oy P.O.BOX 201, FI Varkaus, Finland ABSTRACT Recent changes in the European utilities market have suggested that there are new requirements for the way that power plants operate. Coal and lignite fired power plants may no longer be used as base load plants, but instead will be used to support grid operators by adopting a new type of flexible operation. However, in order to meet this requirement, boiler and turbine technology needs to be developed so that boilers are able to use of mixtures of solid biomass fuels whilst fulfilling load change requirements and meeting stringent emission limits. In 2010, the Swiss utility company Alpiq awarded a 135 MW e lignite fired EPC power plant contract to Kraftanlagen München (KAM) for the Kladno power plant in the Czech Republic. The project was designed to replace old technologies with a more efficient and environmentally cleaner plant, producing energy for the local community whilst meeting the requirements of flexibility from the electrical grid system. For the boiler at the Kladno power plant, Alpiq required CFB boiler technology that was specifically designed to co-fire lignite and biomass. Despite the hardships that the project suffered, such as adverse weather and flooding, the Kladno power plant was developed in accordance with the original time schedule and was taken into hot commissioning and optimising operation during the summer of The Kladno power plant achieved full commercial operation at the end of 2013 as planned. After introducing the reasons behind the changed requirements in the European utilities market, as well as the technical challenges of firing solid biomass and residue in utility boilers, this paper presents the advanced technical features that are present in CFB boiler at the Kladno power plant. This paper will also share the initial successful operational experiences at the Kladno power plant. Keywords: CFB technology, Lignite, Biomass, Renewable Energy

2 1 INTRODUCTION In the European utility markets, new requirements are being developed for the operation of power plants. Global developments in the energy sector have led to increased pressure in the European utilities market to develop power plant technology that is able to achieve increased operational flexibility without sacrificing high operational efficiency. One of the reasons for this change is the Shale gas boom in the US. The boom has had a large impact on the European utilities market because it has lowered the coal price in Europe, effectively making coal and lignite fired power plants more economical than gas plants. Furthermore, initiatives for reducing greenhouse gas emissions that have been implemented in Europe, have resulted in an increase in the use of mixtures of biomass with other solid fuels. Thus, the price of CO 2 remains relatively low in the Emission trading system, currently being below 5 /ton, which leads to the favouring of coal firing. At the same time, environmental legislation, such as the Industrial Emission Directive (IED), have tightening emission limits for large combustion plants. RES (Renewable Energy Sources) targets have also caused a shift in the European utilities market by creating an increase in the use of renewable sources of energy, such as solar and wind. However, although RES subsidies and the revision of European long term energy policy are currently under discussion in several countries, there remains the problem that RES alone cannot adequately meet the challenges of stable network operation, thus resulting to increased power fluctuation and peaks in the power grid. In order to deal with the need for solid fuel fired power plants, the European utilities market has increased the requirements for solid fuel fired power plant operation and control dynamics. Several countries are also currently discussing capacity market systems to compensate for the idle time in thermal capacity. As a result of the above developments in the global energy sector, European utilities have developed new requirements for the operation of power plants. Coal and lignite fired power plants will no longer be used as base load plants, but instead will be used to support grid operators by adopting a new type of flexible operation. This means that boiler and turbine technology now needs to be able to increase the use of mixtures of solid biomass fuels whilst fulfilling the load change requirements and meeting the stringent emission limits. The Kladno power plant and its boiler design, which is presented in the following chapters, is ideally suited for this type of flexible operation. The Kladno power plant is fully capable of responding to the continuously increasing market demands of operational flexibility, high efficiency and multi fuel firing with low emission levels.

3 2 THE LARGE SCALE CFB BOILER FIRING LIGNITE AND BIOMASS AT THE KLADNO POWER PLANT The recent changes in the European utilities market discussed above have led to an increase in the demand for larger coal/lignite power plants which are co-fired with biomass in order to achieve increased efficiency, extended availability and increased fuel flexibility. Due to its inherent fuel flexibility, CFB boiler technology has proven to be ideal for large scale power generation using a broad range of solid biomass fuels, either alone or co-fired with fossil fuels. Foster Wheeler has progressively developed, advanced and scaled-up its CFB technology for coal and biomass co-firing since the 1970s, when its small multi-fuel boilers firing the residue from Nordic wood were used in the pulp and paper industry. Foster Wheeler s CFB boiler concept for the Kladno power plant was the next step in Foster Wheeler s continuous development work and the evolution of its boiler technology. 2.1 The decision to use CFB technology Alpiq s decision to use CFB technology was made at the early stages of the planning process. The planning of the modernisation work at the Kladno power plant started in 2006 and several options were examined in order to improve the efficiency of the plant. Even at this early stage, CFB technology was recognised as a viable technology to achieve improved efficiency for co-firing brown coal and biomass at the Kladno site. However, it was the unique capability of CFB technology to utilize low cost fuels, mainly lignite together with solid biomass fuel, together with its high operational flexibility and low emission level, which led Alpiq to make the decision that CFB technology was to be used as the technology for the Kladno power plant. 2.2 The Kladno CFB boiler design The Kladno boiler represents the next generation of utility power boilers and is specifically designed to co-fire lignite and biomass with the capability to adapt to sudden load change requirements in the electricity grid. The design of the new Kladno CFB boiler (Figure 1) utilises solids separators built from steam cooled panels integrated with the combustion chamber, which avoids the use of heavy refractory linings in the separator. The final superheating stage, as well as the final reheating stage, is INTREX TM type heat exchangers located in special enclosures at the bottom of the furnace adjacent to the main combustion chamber. The INTREX TM heat exchangers are located outside of the main combustion area, which

4 enables them to be used as the last superheating and reheating stages. This results in higher steam temperatures, since the INTREX TM heat exchangers are protected from the fouling and corrosive environment of the boiler s hot flue gas. INTREX TM heat exchangers also provide high load-following capabilities and turndown ratios. Figure 1. Kladno K7 CFB boiler design The design basis of the Kladno boiler is presented as tables 1-3. Table 1. Kladno fuel data DESIGN FUEL DATA Lignite Biomass Sulphur 1,35% d.s. 0.13% d.s. Nitrogen 0,67% d.s. 1% d.s. Moisture 26,6% a.r 40% a.r Ash 19,78 % d.s. 3,33% d.s. LHV 15,61 MJ/kg 9,7 MJ/kg

5 Table 2. Kladno boiler design performance DESIGN PERFORMANCE Flue Gas Exit Temperature 130 C Boiler Efficiency 93,2% Emission * Guarantees 40 % to 100 % BMCR ½ hour average - NO x <190 mg/nm 3 - SO 2 <190 mg/nm 3 - CO <95 mg/nm 3 - NH 3 <10 mg/nm 3 (slip cat. installed) - NH 3 <20 mg/nm 3 (w/o slip cat.) Particulate Matter <20 mg/nm³ *) Emissions expressed in dry 6%O2 Table 3. Kladno boiler steam data STEAM DATA Total Heat Output 303 MW th Steam Flow 105/102 kg/s Steam Pressure 133/33 bar(a) Steam Temperature 541/541 C Feedwater Temperature 251 C The new Kladno K7 lignite firing CFB boiler unit replaced an old coal-fired unit, which was commissioned at the Kladno power plant in the late 1970 s. The new unit will be operated alongside two 135 MW e CFB units, which were previously commissioned in the 1990 s, and is located adjacent to the old boilers. This allows the new boiler to utilise many of the existing plant systems, such as the coal handling and water treatment plant. Foster Wheeler s scope of work for the CFB boiler included the design of the boiler; the delivery of the boiler house enclosure with its steel structures, the boiler pressure parts, the auxiliary equipment, the lignite crushers, the fuel silos for solid biomass fuel and lignite, the fuel feeding equipment for biomass fuel and lignite, and the bag filter; the erection and construction of the boiler; and the start-up, performance testing and commissioning of the boiler. The time schedule that was adopted for the project is presented in Table 4.

6 Table 4. Project execution schedule Contract Award December 2010 Start of Erection November 2011 Commercial Operation December 2013 The main fuel utilised for the new CFB boiler at the Kladno power plant is lignite obtained from a local mine (Bilina). The CFB Boiler is designed for biomass co-firing of a maximum of 10 % heat input. Despite the fact that the lignite is obtained from only one source, there is substantial variation in the fuel quality, especially in terms of in-organic matter, which results in a dry solids range of 13 to 30 %. For biomass, the variation is even wider, giving a moisture range of 25 to 55 %. The CFB boiler s ability to use fuel with such a wide variation in quality clearly demonstrates its excellent fuel flexibility. The design for the Kladno CFB boiler is based on well proven Foster Wheeler CFB technology. Foster Wheeler has experience with more than 430 reference units and the number and size of this advanced CFB technology has grown steadily. The new Kladno CFB boiler incorporates Foster Wheeler s latest design of the solids separator build from water or steam cooled panels integrated with the combustion chamber and features INTREX TM superheaters. The solids separator has shown to achieve performance that results in a high solids circulation rate and a uniform combustion temperature profile over the whole operation range. 2.3 Water and Steam Circuitry In the new Kladno CFB boiler, the feed water enters the boiler at a temperature of 251 C for preheating in a bare tube economizer. Following this, the water enters the steam drum and evaporator surfaces. The steam drum and evaporator surfaces consist of furnace water walls, water-cooled enclosure walls (INTREX TM heat exchangers), and evaporative wing wall heat surfaces inside a furnace. The saturated steam then leaves the steam drum and is led firstly to two parallel steam cooled solids separators, then to cross-over-ducts and then to enclosure walls of the convection cage. Following this, the steam enters the tube coils of the first convective superheater (SH I) located in the 1 st back pass of the boiler. The steam is then further superheated on the wing-wall superheaters (WW SH II) inside the furnace enclosure, adjacent to furnace front wall. After this process is complete, the next stage of superheating takes place in the convective section of the boiler in SH III located as a first heat surface in the boiler s 1 st back pass. Finally, the fourth superheating stage utilises the heat generated from the circulating solid in the INTREX TM superheater tube bundle integrated in the solids separator return channel at the lower part of the furnace. Three stages of desuperheaters are also used in the new Kladno

7 CFB boiler for controlling the steam temperature within the HP steam path. Live steam is led from the final superheaters into a HP-section of the steam turbine and is brought back to the boiler for reheating. The first two stages of the reheating take place on a convective pass of the boiler in the convective reheaters. The circuit final stage of reheating then takes place in the INTREX TM tube bundle. The Kladno boiler uses a RH I bypass for reheated steam temperature control. At higher loads, part of the reheat steam bypasses the RH I which reduces the heat pick-up and decreases the inlet steam temperature to RH II. This patented reheat steam control method avoids the use of a spray control for the reheat side and does not cause any decrease in plant efficiency. There are currently more than 20 CFB boilers that utilise this control method, including the CFB boiler at the Łagisza power plant (the first OTU-CFB unit build), and the CFB boiler at the Polaniec power plant (the world s largest purely biomass fired CFB). Due to the requirement for the full reheated steam temperature to be at a load range between 60 to 100 % MCR, the RH I bypass control is supported by a spray water injection at higher loads in the Kladno CFB boiler. For live steam, the range of full superheating is started from 50 %-MCR. 2.4 Auxiliary Equipment The Kladno CFB boiler is required to meet strict environmental limits when providing electricity grid support services. This was taken into account when Foster Wheeler designed the auxiliary equipment for the Kladno CFB boiler. The combustion air system for the Kladno CFB boiler consists of a primary and secondary air system and a separate air system for fluidizing the INTREX TM heat exchangers and sealing devices. Radial fans with speed and inlet guide vane control were used for the primary and secondary air fans. Having combined speed and inlet vane control means that the air system is able to have a quick response in transient operation conditions whilst still being economically feasible. For controlling gaseous emissions, the Kladno CFB boiler utilises a low and uniform combustion temperature, as well as staged combustion. These are two of the well known benefits of CFB boiler technology. In addition, the Kladno CFB boiler is equipped with an ammonia dosing system (SNCR) with an ammonia slip catalyst at the boiler s 2 nd back pass for controlling the NO X emissions, as well as a limestone feeding system for controlling the SO 2 emissions. The Kladno CFB boiler ammonia feeding system consists of a 60 m 3 ammonia-water tank, feeding pumps and feeding lances, which are installed to the furnace walls and to the solids separators. By using multiple

8 ammonia feeding levels in the boiler furnace and in the separator, ammonia can be always be fed into an optimal temperature region in order to achieve NO x reduction. Excessive NO x excursions during transient conditions are also avoided. This is an important feature because the new Kladno CFB boiler unit has to carry out grid frequency support services whilst keeping ½ hour emission averages below the environmental limits. The limestone feeding system comprises of an 800 m 3 limestone silo and feeding lines into a furnace. Even distribution of the limestone into the furnace, favourable conditions for DeSO x in the boiler hot loop, as well as a long residence time of the limestone particles help to guarantee a high reduction of SO 2 in the furnace with a reasonably low ratio of calcium and sulphur. A Bag Filter (BF) is used to control the particulate emissions and ensures that emissions are kept below 20 mg/m3n. The separated fly ash is moved to a fly ash silo using a dense phase pneumatic conveyor system. The solid fuel feeding system of the new Kladno CFB boiler consists of separate feeding equipment for lignite and biomass. Both systems use two final feeling screws, which allows both the lignite and biomass to be fed into the same feeding points on the furnace front wall. Lignite is transported from the fuel yard to the boiler day silos by means of a belt conveyor. The lignite feeding system inside the boiler house consists of lignite crushers on top of the day silos, two day silos, lignite feeders below the silos, and dragchain conveyors for distributing the lignite among the furnace long walls. In total there are six feeding points at the lower furnace, three points on the furnace rear and three on the front wall. In addition, the system allows the use of both feeding lines from one silo by means of crosswise drag-chain conveyors. Solid biomass fuel from the fuel yard is brought to one silo by means of a belt conveyor. From the silo, biomass is fed onto a drag-chain conveyor by means of a silo reclaimer at the bottom of the silo. A second drag-chain conveyor distributes the biomass along the front wall of the furnace. 3 EARLY OPERATING EXPERIENCES 3.1 Cold Commissioning, Chemical Cleaning and Steam Blow out Cold commissioning of the new Kladno CFB boiler was started at the beginning of 2013 whilst some minor erection works were still ongoing, and the mechanical completion of the boiler was achieved on the 15 th of April Chemical cleaning of the power unit was completed on the 7 th of May followed by magnetite film formation and refractory curing. The steam blow out of the boiler was accepted on the 6 th of June, 5 days ahead of schedule, despite the delays caused by adverse weather and heavy floods in the locale of the plant. After the completion of restoration works, the CFB boiler achieved a readiness for bypass operation at the middle of June, all within the original project schedule.

9 3.2 Hot Commissioning and Boiler Optimisation The first step of the optimisation period was to work out the optimised operational conditions for the boiler. This was important in order to achieve the required operation of the boiler over the whole load range, minimise the consumption of ammonia and limestone, and maximise boiler and unit efficiency. This was achieved by working out how to reduce the losses and by optimising auxiliary power consumption and RH desuperheater flow. By achieving a low and uniform combustion temperature over the whole load range the performance of the boiler is also increased as uncontrolled NO x emissions remains low, low excess air can be used without compromising performance of the DeSO x, and there is elimination of the risk of decreased combustion efficiency via increased unburned material in the ash. In addition, low combustion temperature decreases the costs for maintenance due to the decreased flue gas velocity and the lower temperature gradients in the boiler hot loop. After the combustion process for the Kladno CFB boiler was adjusted, optimisation of the boiler s dynamic performance began. The new Kladno plant is a modern utility power plant which is required to frequently support the electrical grid whilst achieving tight emission limits and high efficiency. These requirements provide a target for the operation of the boiler in transient and steady state operating conditions. In addition to the preceding requirements, the Kladno K7 CFB boiler is also designed to provide a maximum of 105 MW of heat to the district heating network. The purpose of the CFB boiler dynamic optimisation was firstly to meet the performance required for the primary and secondary support of the electricity grid, meaning a unit load change rate of 4MW e /min over the whole load range. The new Kladno CFB boiler is fitted with the possibility for condensate throttling during load changes in order to support the possibility to provide primary support to the electricity grid. Secondly, dynamic optimisation aims to meet the requirements set for the boiler controls, e.g. the main steam temperature and pressure control, as well as the reheated temperature control. However, most importantly, the dynamic optimisation aimed to ensure that the boiler met the emission limits in transient conditions. The dynamic optimisation included tests for run backs, house load operation etc. and readiness for the Grid Tests was demonstrated by the boiler during preliminary tests held at the beginning of November. Following this, the dynamic performance of the new CFB boiler was finally demonstrated in Grid Tests at the end of the November. The following Figures (2-4) show the testing of the Kladno K7 CFB boiler for the purpose of the Primary and Secondary support of the electricity grid. The first Figure illustrates the electrical grid secondary support capability whilst simultaneously extracting steam for district heating. The Ramp speed in the test was 4 MW e /min. In the second Figure, primary support capability is shown with maximum and minimum generator output. These tests were part of the grid code certification tests completed in late November

10 2013. Figure 2: Kladno new CFB unit load changes between minimum and maximum load Figure 3: Kladno new CFB unit grid Primary Support tests at full and minimum load

11 Emissions during the Secondary Support test of the Kladno CFB unit are shown in the following Figure 4. Figure 4: 1/2 hour average emissions of the Kladno CFB during the electrical grid Secondary Support testing program 3.3 Grid Tests Grid code certification tests for the Kladno K7 CFB boiler were carried out between the 25th and the 27th of November The tests included tests on the boiler s capability for Primary and Secondary Support of the electrical grid, tests on operation of the boiler island, and tests on the influence of heat extraction. Grid code certificates for the CFB boiler were issued at the end of November 2013.

12 3.4 Biomass Co-firing The optimisation of the CFB boiler during the autumn of 2013 was conducted purely with lignite due to the limited availability of biomass at that time. As a result, biomass co-firing was tested in the Kladno CFB boiler for the first time at the beginning of November 2013 and more comprehensive tests were carried out in early In those tests, biomass was co-fired with lignite up to a maximum share of 10 % of the heat input. Operation of the Kladno CFB boiler in the tests demonstrated that it was highly efficient with biomass co-firing over the entire load range. The process was stable and the biomass and lignite achieved steam pressure control. In comparison to pure lignite firing, consumption of ammonia-water and limestone was also slightly reduced with biomass co-firing. Since beginning biomass firing, it has become a permanent part of the fuel palette in the Kladno power plant, demonstrating once again the excellent fuel flexibility of CFB boiler technology. 3.5 Performance Test, Hand Over and Commercial Operation In December 2013, Performance Tests for the Kladno CFB boiler were performed. These tests included testing of the most important boiler performance guarantees (thermal efficiency, auxiliary power consumption, ammonia-water and limestone consumption and emissions). The CFB boiler s Performance was tested in MCR and minimum load points. According to the preliminary results, all of the performance guarantees have been fulfilled within a large margin, demonstrating that CFB boiler technology is able to meet and surpass all the requirements set for a modern utility power unit. Once the new CFB boiler had demonstrated its performance in the performance tests for steady state operation and in grid code certification tests for dynamic behaviour, it was handed over to the customer and taken into final commercial operation at the end of Since starting commercial operation, the Kladno CFB boiler has continuously participated in electrical grid support while simultaneously providing heat into the district heating network. The typical operation of the CFB boiler unit at Kladno and its gaseous emissions over a 48 hour period are shown in Figure 5.

13 Figure 5: Typical load profile of the Kladno K7 boiler and ½ hour average emissions 4 LARGE SCALE CFB FOR COAL AND BIOMASS CO-COMBUSTION STATE- OF-THE-ART MW e utility CFB for co-combustion of solid biomass fuels and coal CFB boiler design for sub-critical coal and solid biomass fuel co-firing is currently available at a size of up to 600 MW e with steam temperatures of over 560 ºC. Supercritical CFB is offered at a size of up to

14 800 MW e for bituminous coal with a possibility to co-fire 20 % biomass. Both these options meet the highest requirements for plant efficiency and environmental performance. CONCLUSIONS Circulating Fluidized Bed boilers (CFB) are ideal for efficient power generation. The boiler technology means that CFB boilers are capable of co-firing a broad variety of solid biomass fuels along with lignite in large utility power plants. The Kladno CFB boiler represents the next generation of flexible utility power production. The boiler is designed to co-fire lignite and biomass with the capability to adapt to sudden load change demands in the electricity grid and meet the high emission reduction requirement. After starting commercial operation in December 2013, the first operational experiences of the CFB boiler in the Kladno power plant have been excellent. According to the preliminary results, all of the performance guarantees have been completely fulfilled within a large margin, thus demonstrating the excellence of the Kladno CFB unit. The boiler is able to meet and surpass all of the requirements set for a modern utility power plant. The CFB technology is the ideal choice in meeting the European utility market s demand for fuel flexibility both now and in the future. It is a proven technology to utilise a broad range of coal, lignites and solid biomass fuels in large scale power generation.

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