Powerful. Performance. At Home in Energy Plant Engineering POWERFUL PERFORMANCE

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1 Powerful Performance POWERFUL PERFORMANCE At Home in Energy Plant Engineering

2 From Coal to Electricity Generation of electricity in a typical coal power plant Before being injected into the furnace, the raw coal is crushed down to a fi ne pulverized form in the coal mills. Flue gases up to 1,450 C arise from pulverized fuel combustion in the steam generator furnace. The liberated heat is used to generate high-pressure and high-temperature steam. The steam is directed to a turbine; it fl ows onto the blade wheels and turns the turbine shaft. An attached generator then generates the electrical power. With the help of catalysts, the nitrogen oxides in the fl ue gas react in the DeNO X system to produce nitrogen and water vapor. Ash particles adhere to electrically-charged surfaces in the electrostatic precipitator; they are rapped and removed from the fl ue gas. In the fl ue gas desulphurization system (FGD) lime slurry or suspended pulverized limestone bind the sulphur dioxide coming from the fl ue gas. The fi nal product arising is gypsum. 2

3 Contents Energized As an energy plant constructor with a long track record, Mitsubishi Hitachi Power Systems Europe benefits from the boom in power plant engineering. from page 4 Our Staff From engineers to technicians: our emphasis is very much on team work. from page 10 Our Projects Whether at home or internationally, we build power plants and supply components to many regions. from page 16 Our Products Whether it be pressure parts, firing technology or steel structures, we have our own manufacturing facilities for them. from page 26 Our Know-How New materials and energy storage technologies form the basis for tomorrow s power plant. from page 36 At Home in Energy Plant Engineering 3

4 Energized With a track record going back over 100 years, energy plant constructor Mitsubishi Hitachi Power Systems Europe GmbH benefits from the rising demand for electricity and the worldwide boom in power plant engineering. En

5 ergized Mitsubishi Hitachi Power Office, Duisburg

6 Mitsubishi Hitachi Power Systems Europe Some 900 people work in the offices at the Duisburg Inner Port Stakeholders in Mitsubishi Hitachi Power Systems Europe GmbH MHI MHPS MHPSE Hitachi, Ltd. 65% 35% 100% A track record going back over 100 years in the power plant field, efficient products, a highly motivated workforce and a parent company of real strength and substance: that is Mitsubishi Hitachi Power Systems Europe GmbH (MHPSE). The energy plant constructor both designs and builds fossil-fired power plants and through its references ranks as one of the market and technology leaders. MHPSE also supplies key components, such as utility steam generators, environmental engineering equipment, turbines and pulverizers. Mitsubishi Hitachi Power Systems Europe s history goes back to 1898 and the establishment of Deutsche Babcock & Wilcox Dampfkesselwerke AG in Berlin. In 2003 Babcock-Hitachi K.K., a subsidiary of Hitachi, Ltd., acquired the power engineering field and the entire know-how in steam generation and combined-cycle power plants of the former Babcock Borsig Group, Oberhausen. Following complete takeover by the Hitachi Group, the company was renamed Hitachi Power Europe GmbH in In 2013 the company then started operations as Mitsubishi Hitachi Power Systems Europe GmbH as part of the joint venture of Mitsubishi Heavy Industries, Ltd., and Hitachi, Ltd. In 2007 the energy plant constructor set up its head offices at the Inner Port of Duisburg / North Rhine-Westphalia. Including subsidiaries, approx. 2,000 staff are on the company s payroll (As of: March 2014). Along with power plant engineering and supplying key components, the plant constructor also concerns itself with forward-looking services. Green technologies in energy storage and biomass, for instance are examples of Mitsubishi Hitachi Power Systems Europe innovation and reliability. 6

7 Internationally on the Go Mitsubishi Hitachi Power Systems Europe GmbH is a 100 % subsidiary of Mitsubishi Hitachi Power Systems, Ltd. (MHPS) a joint venture of Mitsubishi Heavy Industries, Ltd. und Hitachi, Ltd. MHPS is a globally operating energy plant constructor with a total of 58 subsidiaries (9 in Japan, 49 outside Japan). The joint venture has an approx. 23,000 workforce (consolidated) and its aim is to become the worldwide No. 1 in conventional power plant construction. A mainstay of this corporate group is Mitsubishi Hitachi Power Systems Europe GmbH which in designing and constructing fossil-fired power plants (coal, gas) ranks amongst the market / technology leaders in its operating regions. SUBSIDIARIES AND RELATED COMPANIES OF MITSUBISHI HITACHI POWER SYSTEMS EUROPE 1 Mitsubishi Hitachi Power Systems Europe MH Power Systems Europe Service GmbH 3 Mitsubishi Hitachi Power Systems Africa (Pty) Ltd. 4 Meeraner Dampfkesselbau GmbH 5 Donges SteelTec GmbH 6 Babcock Fertigungszentrum GmbH 3 Energized 7

8 Development Costs Energy Given rising populations, a growing economy and new products no development is possible without energy. And it is principally electrical energy that is power which is needed for the production and transportation of merchandise, products and services. Competitive economic systems rely on a healthy mixture of various fuels and a raised level of energy efficiency. Most of the electricity is generated in the world by fossil fuel-fired power plants after all, they are tried-and-tested, reliable under continuous operations and economical to run. In particular, the latest generation of coal, lignite and gas-fired power plants ensure that environmental pollution is kept well down. An added plus: fossil fuels, such as coal and lignite, are available for supply in many politically and socially stable countries and their reserves will last for literally hundreds of years. DEVELOPMENT OF COAL CONSUMPTION (in million tons) 3,646 World 5,522 China 1,317 2,543 India OECD* 1,451 1, *30 primarily Western industrial countries Source: IEA, estimated figures for 2007 Currently, the world has a population of approx. 6.8 billion people. The world s population has doubled within the last 50 years and will continue to increase. Moreover, a quarter of mankind is still without electricity. For this very reason electricity consumption is set to rise more rapidly than all the other forms of energy consumption. Experts expect a doubling of electricity requirements by Hence, the challenge facing companies, the political world and society in general is quite clear: everything must be done to ensure that energy is generated sustainably, reliably and economically. THE SHARE OF COAL IN THE GENERATION OF ELECTRICITY (%) Poland Australia China India Czech Republic USA * 93 Source: IEA, all figures for 2006 except * for

9 Tops in Power Plant Construction It is no surprise on account of its long tradition, ultra up-to-date products and immense know-how that is one of the top countries for the construction of energy plants. This is very much down to the world s highest efficiencies for fossil-fired power plants, tough environmental protection provisions and the leading role taken in researching and developing new, more productive materials and CO 2 capturing technologies. The demand for both new and replacement plants is considerable given the global rise in electricity consumption and the fact that many power plants will be reaching the end of their service lives over the next few years. It thus comes as no surprise to find that the power plant industry is booming. In the EU countries alone with approx. 752,000 megawatts (MW) of installed electricity generating capacity it is expected that 300,000 MW will have to be replaced by The major plant construction business in (power plants, iron & steel works and rolling mills, electrical equipment, cement units) is also a major export factor as shown by the fact that some 80 % of the orders come from the international markets. All these factors will continue to bring about an increase in the demand for products and know-how from the energy plant engineering / power plant sectors. TOTAL ORDER INTAKE BY REGIONS (2012) The boom in major plant construction is principally down to orders from abroad Industrial countries 16.2% 19.0% Rest of the world 20.5% Asian / 23.8% Pacific Region Eastern Europe 11.6% and CIS 8.8% Middle East Source: Arbeitsgemeinschaft Großanlagenbau in the VDMA TOTAL ORDER INTAKE IN MAJOR PLANT CONSTRUCTION 1970 TO 2012 (in EUR billion) 35 Total Abroad Source: Arbeitsgemeinschaft Großanlagenbau in the VDMA Energized 9

10 Our

11 Staff Our Staff From the engineer to the commercial employee, from the technician to the project assistant: emphasis is very much on team work at Mitsubishi Hitachi Power Systems Europe.

12 Designing with Ultra Modern Software Special IT tools image power plants and components both virtually and in 3D Energy plant constructor Mitsubishi Hitachi Power Systems Europe specializes in power generation in highly-efficient coal and lignite-fired plants. In addition, turnkey gas and steam power plants tailored to customer requirements form part of its work & services. Whether it is a utility steam generator, turbine, coal mill or environmental engineering, each and every power plant consists of numerous components which must be operated productively, reliably, economically and in an environmentally compatible manner. In design work, MHPSE makes use of the most up-to-date IT tools for optimum plant planning. These tools 3D CAD software and virtual reality solutions, for instance are vital in optimizing plant arrangement and calculating flows in a utility steam generator furnace. This makes it possible, amongst other things, to raise in advance the service lives of system parts and thus save on costs. Mitsubishi Hitachi Power Systems Europe both uses and refines design software for the construction and commissioning of power plants and components. It should, in future, be possible to image a complete power plant virtually on the computer inclusive of all the ongoing data and readings. A number of benefits would arise from this dynamic simulation of an overall plant. One of them would be to train staff for their tasks and another would allow simulation of vital processes starting up a power plant, for instance, following an inspection at the computer. 12

13 Our Own Installation Teams on Site Mitsubishi Hitachi Power Systems Europe has an extensive track record going back over many years in energy plant engineering both in and abroad. Our installation teams concern themselves not only with planning / design and engineering but also with monitoring work at the project sites, controlling logistics and personnel needs, carrying out continuous controlling and ensuring there is no trouble in placing components into service. Mitsubishi Hitachi Power Systems Europe not only supplies its own components and replacement parts for coal mills and burner technology, for instance, but also undertakes plant servicing. The competence and know-how needed for power plant component maintenance and upkeep is bundled in our own service division. Experienced Mitsubishi Hitachi Power Systems Europe staff supervise power plant construction Our Staff 13

14 Looking for Traces Samples are analyzed both under a scanning electron microscope and in the chemistry laboratory The scanning electron microscope sheds light on the matter even the most minute traces become clearly visible when magnified 100,000 times. This is a factor of real significance when the fractured surfaces of materials, for instance, are examined. But this is only one of a number of tasks which the staff in the Mitsubishi Hitachi Power Systems Europe laboratory concern themselves with on a daily basis. The experts in material technology and chemical analysis make use of the most up-to-date equipment. They examine and analyze fossil fuels, determine, for example, the calorific value and grindability of various coal types and look for trace elements in combustion residues (in slag and ashes, for instance). Their aim is to both improve combustion and, at the same time, cut back on environmental pollution. This can be achieved, for example, by optimizing the design of coal mills and burners for the various fuel types. Specialists carry out damage analyses and remaining service life investigations something involving the examination of hundreds of material specimens every year. They check on processability and ensure that any newly developed materials are suitable for future power plant generations. That is why close collaboration with those involved in projects / design work and with commissioning engineers is something quite natural for the laboratory s staff. The Mitsubishi Hitachi Power Systems Europe laboratory is accredited in keeping with DIN EN ISO / IEC

15 Motivated Employees Fresh trainees get to know accompanied by company representatives the various departments; including the MHPSE laboratory Exceptionally well trained employees working independently at a knowledge level this is where the success of any company can be found. Here Mitsubishi Hitachi Power Systems Europe provides the best-possible prerequisites for both those starting off in the company (trainees, student trainees, university graduates) and for our long-standing colleagues. The company is popular as an employer particularly with young people. As a result, around 50 young people apply, on average, for each training post. Standing as confirmation for the high-quality of the training is the fact that practically all trainees are allowed to prematurely take their final examinations in view of their good grades. Mitsubishi Hitachi Power Systems Europe also sustainably invests in further / ongoing training for company employees in response to requirements. For both company employees and management, specific, Group-wide training steps provide a wide range to choose from. The international scope of MHPSE as an energy plant constructor with projects extending from Europe to South Africa and India widens the personal and professional horizons of our staff. Thanks to international assignments, they get to know different approaches to work and thus make use of their full potential. After all, the basis for constant innovations can only be accomplished by motivated and qualified staff. Training also includes visiting a power plant site Our Staff 15

16 Our Projects Whether it is in, Europe or in the rest of the world, we build power plants and supply components to many regions. Our P

17 rojects Bituminous coal plant Maasvlakte / Netherlands

18 Specialist for the Power Train The Power Train comprises the major components of a power plant The three components utility steam generator, flue gas cleaning equipment and turbine / generator (including their balance-of-plant equipment) form the Power Train of a power plant. Energy plant constructor Mitsubishi Hitachi Power Systems Europe specializes in designing, con struct ing and commissioning such power trains. MHPSE has an extensive track record in unit sizes to over 1,000 MWel in conventional power plants (coal, gas and oil-fired boilers complete with steam turbines). Moreover, MHPSE can quote some 20 references for turnkey gas power / combined-cycle plants in Europe and the Near East with an installed capacity of approx. 4,500 MW. Our specialists know-how extends across all the steps needed for designing and construction including: Approval planning (preparing approval applications, consultations with public authorities) Concept-making (incl. feasibility calculation, benchmarking, cycle operation simulation) Basic and detail engineering (from process engineering through to electrical engineering, instrumentation & control and plant layout) Project management (scheduling, expediting, cost tracking, quality assurance) Purchase support 18

19 45 %+ Degree of Efficiency Whether it involves power plants, the power train or utility steam generators Mitsubishi Hitachi Power Systems Europe has the required experience and know-how to meet customer-specific requirements in power plant engineering. As a fully fledged energy plant constructor, the company is in a position to supply individual components and also to plan, erect and start up complete plants. Since 2007, Mitsubishi Hitachi Power Systems Europe has placed over 20,000 MW of installed capacity either into service or is engaged in its construction. An example here is the Moorburg coal power plant with MHPSE constructing the two utility steam generators for the double-unit system for customer Vattenfall in the port of Hamburg. On completion, the power plant will have a 45 %+ efficiency and then be one of the most modern of its kind in the world. The high net efficiency provides not only a considerably greater output but also saves on resources (less fuel used) compared to power plants to date and reduces the specific CO 2 emissions. SPECIFICATIONS OF MOORBURG UNITS A / B Power output Fuel Live steam parameters 2 x 820 MW bituminous coal 600 C / 276 bar Net efficiency over 45 % Boiler house height 100 meters Total weight pressurized part per unit 3,900 t Project Moorburg Our Projects 19

20 At Home in Lignite It is not only coal power plants but also lignite-fired ones which can guarantee an assured supply of electricity around the clock. Over the past few years various energy suppliers have either started to modernize their lignite power plants or to rebuild them. On account of its many years of experience with this fuel, Mitsubishi Hitachi Power Systems Europe has established itself as a supplier of the latest generation of highly efficient utility steam generators for these projects. For example: the two new RWE Power AG power plant units (total 2,240 megawatts capacity) at the Neurath site. This is where Mitsubishi Hitachi Power Systems Europe, as consortium leader, is erecting two utility steam generators with an efficiency up to 43 % a peak figure worldwide. The two units represent the latest stage reached in steam generator technology across the world. They feature supercritical steam pressures and the highest steam temperatures ever realized for lignite. Mitsubishi Hitachi Power Systems Europe has also erected an ultra-modern utility steam generator for a new lignite power plant unit at Boxberg in Saxony and placed it into operation. Just like other customers, Vattenfall relies on the large lignite reserves which make it possible for lignite power plants to be built and operated. Thanks to the much greater degrees of efficiency, the new plants emit much less CO 2 than today s power plants. At the same time, the plants conserve valuable resources since less fuel is needed for the same quantity of electricity. A further benefit is that Mitsubishi Hitachi Power Systems Europe has its own firing technology components which are optimally adapted to the particular requirements of the various lignite types (e. g. circular jet burners). Example Boxberg: efficient utility steam generator in the lignite power plant 20

21 and with Gas-Fired Plants Short reaction times and particularly high degrees of efficiency both the principles of a gas turbine and steam power plant are united in a combined-cycle power plant. The fact that these extremely efficient plants have both a gas turbine and a (downstream) steam turbine ensures that degrees of efficiency up to 60 % are reached. Combined-cycle power plants come up with peak degree of efficiency figures In gas-fired plants as well, Mitsubishi Hitachi Power Systems Europe has an extensive know-how and a track record going back over many years across the whole spectrum from design, acquisition and construction through to commissioning. The highly successful and globally deployed H-25 / H-15 gas turbines as well as the newly developed H-80 gas turbine from the parent company Hitachi, Ltd. are just right for a reliable, efficient and economical operation of the power plants. MHPSE engineers are also very familiar with large combined-cycle plants. As general contractor, Mitsubishi Hitachi Power Systems Europe erected a combined-cycle power plant with an integrated district heating supply system. This combined operation is responsible for up to 89 % of the gas energy being utilized. In this project Mitsubishi Hitachi Power Systems Europe staff were responsible for the overall plant layout, constructional planning / implementation, installation and commissioning. During construction, the engineers surmounted considerable challenges such as integrating the plant into the building of a former coal power plant and the ground water level. The power plant is the replacement for the existing Scandinavian coal-fired plants and will see carbon dioxide emissions going down every year by around 1 million tons. Our Projects 21

22 Highly Efficient Boilers Two examples of highly efficient utility steam generators from Mitsubishi Hitachi Power Systems Europe: Neurath (top) and Datteln (bottom) Thousands of welds, hundreds of miles of pipes, several ten thousand tons of steel structures: the heart of every fossil-fired power plant is the utility steam generator (boiler). This is where the pulverized fuel is combusted at approx. 1,450 C and where the hot flue gases and very hot steam under extremely high pressure (subsequently driving the turbine blades) arise. With a track record going back over 100 years, Mitsubishi Hitachi Power Systems Europe is one of the market and technology leaders in utility steam generators. Our references are made up of over 370,000 megawatts of power plant capacity (180,000 MW in coal firing, 43,000 MW in lignite firing and 140,000 MW in oil and gas firing) installed since MHPSE develops, constructs and supplies steam generators for over 1,100 MWel unit outputs involving 300 bar+ pressures, 600 C live steam temperatures and reheater temperatures up to 620 C for all available fossil fuels. These range from coal / lignite to problematical fuels (e. g. gases from coke ovens / steel works, refinery residues). Utility steam generators are being constantly refined for operation with the use, for instance, of new highly resistant materials under even higher steam temperatures and pressure. In this way, the degree of efficiency of tomorrow s coal-fired power plants can be raised to over 50 %. 22

23 Wide Range of Fuels Whether as pulverizers, burner or deashers, a large number of components are in use in and around the utility steam generator. Mitsubishi Hitachi Power Systems Europe firing systems and components cover a wide range of gaseous, liquid and solid fuels. The corresponding equipment is optimized for both coal and lignite pulverized firing systems. As a designer and manufacturer of original parts, the company is also an ideal partner for modernization work and replacement part needs. Depending on selection criteria (e. g. fuel property, emission standards, ash recycling), MHPSE provides the optimum firing systems for bituminous coal and lignite. For instance, the MHPSE-developed burner generation with its numerous patents features minimum emissions and maximum flexibility. The coal mill feeders in the form of conveying equipment (drag chain and belt conveyors) and steel plate conveyor feeders developed by Mitsubishi Hitachi Power Systems Europe are also designed for top, fail-safe performances. Pulverizers (for grinding and drying bituminous coal and lignite) have been part of the scope of production and services of Mitsubishi Hitachi Power Systems Europe for many years now. Our trade references with burners for gas /oil fired plants or alternative fuels (e. g. blast furnace gases and refinery residues) are based on a lengthy track record on the commercial scale. from l. to r.: DS Burner, RS Burner and DST Burner MPS Mills Our Projects 23

24 Electrical Power for South Africa and India Six utility steam generators for each of the Medupi and Kusile sites are to be delivered (right: Medupi, March 2012) 1 Medupi 2 Kusile 3 Johannesburg Meja 2 Raghunathpur 3 Solapur 1 2 End 2007 / start 2008, South African energy supplier ESKOM ordered 12 coal-fired utility steam generators each with a capacity of 800 MW. Mitsubishi Hitachi Power Systems Europe and Mitsubishi Hitachi Power Systems Africa (Pty) Ltd. our South African subsidiary are constructing the key components at both the Medupi and Kusile power plant sites. This major order is of an approx. EUR 4bn volume with the scope of delivery comprising design engineering, acquisition, erection and commissioning. The utility steam generators will be going on stream as from Once in operation, the utility steam generators will rank amongst the most up-to-date in South Africa. In addition, they will have a significantly improved efficiency over existing plants. Mitsubishi Hitachi Power Systems Europe s commitment in South Africa is of a long-term nature. Many of the components will be designed and manufactured on the spot; in fact, 60% of the order volume will remain in the country as local value added. India is one of the world s most rapidly growing markets for energy plant constructors. The total capacity installed on the Indian sub-continent is set to more than double to approx. 330,000 megawatts (MW) between 2010 and 2017; currently some two-thirds of the power is generated in fossil-fired power plants. Mitsubishi Hitachi Power Systems Europe s first step on this rapidly expanding Indian market turned out successfully in Together with a joint venture partner, MHPSE secured the order to supply six 660 MW bituminous coal utility steam generators. The joint venture ( BGR Boilers Private Limited based in Chennai) was set up in 2010 by Mitsubishi Hitachi Power Systems Europe and Indian plant constructor BGR Energy Systems Ltd. to manufacture and market super-critical utility steam generators on the spot and place them into operation. BGR Energy and MHPSE parent Hitachi, Ltd. had also signed up to another joint venture for manufacturing steam turbines ( BGR Turbines Company Private Limited ). Thus MHPSE, Hitachi and BGR are in a position to operate as a fully-fledged EPC contractor on the Indian market and supply all the major components for power plant construction. 24

25 Polish and Greek Markets Entered In September 2012, Mitsubishi Hitachi Power Systems Europe and consortium partner Polimex-Mostostal (PXM) signed the contract with Polish energy supplier Enea Wytwarzanie for construction of the Kozienice 11 bituminous coal plant. The value of the order for the 1,075 MW plant (net efficiency: 45.5 %) is EUR 1.54bn. MHPSE s scope of supply comprises the utility steam generator including coal bunkers, mills, firing system, flue gas cleaning equipment, the overriding instrumentation & control and a number of ancillary facilities. Parent Hitachi, Ltd. is supplying the steam turbine and related components. Babcock-Hitachi K.K. (BHK) as subcon tractor is seeing to the matter of flue gas desulphurization. PXM is responsible for the construction part, erection work and much of the balance-of-plant. Up to 2,500 people will be working on the site during the construction period and a significant share of the value added will remain in Poland. The new unit will start commercial operations in Mitsubishi Hitachi Power Systems Europe and customer TERNA S.A. are to construct an ultra-modern lignite power plant with a 660 MW installed capacity in northern Greece. Greek energy supplier PPC (Public Power Corporation) signed the contract with plant constructor TERNA in March As TERNA s sub-contractor, MHPSE is responsible for the design engineering, supplying the utility steam generator including balance-ofplant and together with parent Hitachi, Ltd. the steam turbine and the complete flue gas cleaning system. TERNA will construct and place into operation both the power plant and its balance-of-plant. Building is due to start for Ptolemais V in 2015; it will assume commercial operations in Bituminous coal plant Kozienice 11 Lignite coal plant Ptolemais V Our Projects 25

26 Our Products Our own manufacturing facilities providing boiler pressure parts, firing technologies and steel structures make us largely self-sufficient in power plant engineering. Our Pr

27 oductsdonges SteelTec GmbH

28 Greater Autonomy Thanks to Coal mills and burners are built in the Babcock Manufacturing Center in Oberhausen (top, below right) In contrast to most other power plant companies, Mitsubishi Hitachi Power Systems Europe GmbH has its own manufacturing facilities for the major components. These include pressure parts for utility steam generators, headers, coal mills and burners, material handling systems and steel structures. This means that MHPSE is not primarily tied to sub-contractors and creates a true Alliance for Quality. An overview of the three manufacturing facilities: Donges SteelTec GmbH (Darmstadt): one of the leading German steel and bridge construction companies; manufactures steel structures in the power plant field Meeraner Dampfkesselbau GmbH (Meerane): manufactures complex components for utility steam generators (pressure parts, for instance) for power plants Babcock Fertigungszentrum GmbH (Oberhausen): manufactures high-grade components (e. g. coal mills, coal burners, material handling systems) principally for Mitsubishi Hitachi Power Systems Europe GmbH Included in Meeraner Dampfkesselbau GmbH s supplies are pressure parts and headers (left) 28

29 Our Own Production Donges SteelTec GmbH manufactures steel structures for power plants Maximum quality is needed in power plant engineering particularly since components are subject to considerable stresses and must dependably perform their functions for decades under continuous operations. That is why our subsidiaries have established special priorities in controlling production quality. Thanks to constant refinements in high-tech materials involving, for instance, special alloys for pressure parts, components can be used ever more economically and in a more environmentally compatible manner. At the same time, Mitsubishi Hitachi Power Systems Europe specialists work closely together with their colleagues in the production facilities. Power plant projects abroad such as in South Africa or in India often require a large proportion of the components to be constructed and made locally. To this end, Mitsubishi Hitachi Power Systems Europe enters into local cooperation schemes, constructs manufacturing facilities and qualifies the local workforce for the project. The company is also at the cutting edge of matters in general bridge and steel construction Our Products 29

30 A Clean Aspect Whether it is a matter of coal dust collection, desulphurization or denitrification, much of the capital expenditure in building modern power plants goes into environmental engineering. After all, flue gases containing ash particles, nitrogen oxides and sulphur dioxides form during coal combustion. Highly effective processes can cut back these emissions to the greatest possible extent. Modern technology is responsible, for instance, for 99.9 % of the dusts being discharged from the flue gas. Other processes ensure that few emissions arise from the other constituents: Ash particles adhere to electrically-charged plates in the electrostatic precipitator; they are rapped and removed from the flue gas. Nitrogen oxides (NO X ) react with ammonia and with the aid of catalysts are converted in the DeNO X system to nitrogen and water vapor the natural constituents, in fact, of air. Sulphur dioxide can be filtered out in the flue gas desulphurization system (FGD). Lime slurry binds it in the flue gas and the final product is pure gypsum. Mitsubishi Hitachi Power Systems Europe has extensive knowledge available and a long track record in flue gas cleaning. The company can deliver the components turnkey, if needed. In addition, MHPSE and parent companies are constantly researching into new processes to raise flue gas cleaning system efficiencies. The FGD filters sulphur dioxide out of the flue gas 30

31 Still Dependable under High Stresses Faster than sound: the blade tips of a turbine rotate approx. 3,000 times a minute. Even though subject to extreme stresses from the extremely hot (up to 620 C) steam under very high pressure (up to 250 bar), the blades they still have to dependably function around the clock. Highly efficient steam turbines are supplied by our parent companies A new Hitachi development: the H-80 gas turbine For over 75 years now, our parent companies have been supplying highly efficient 250 to 1,380 MW steam turbines. The turbines and generators are manufactured in Japan. Comprehensive research, refinements, improved design and manufacturing technology ensure that they belong to some of the best of their type in the world. Tough quality checks are carried out by engineering teams to ensure maximum performance and quality. These teams also provide continuous and extensive support for customers and also service and modernize the systems. Another success story comes in the form of the H 25 / H 15 gas turbine developed by Hitachi, Ltd. Designed as a heavy duty machine (30 MW rating class), over 150 gas turbines of the H-25 / H-15 type are in service throughput the world in power plants. The H-80 newly developed gas turbine from Hitachi has also been in use for power production purposes since the beginning of The gas turbines are sound and reliable under continuous operations, require little maintenance outlay and are admirably suited for cogeneration / district heating supply plants. Hitachi gas turbines are also used as drive turbines in industry (e. g. mineral oil business). Our Products 31

32 Our Service Supplying spare parts, upgrading components, raising efficiencies and extending service lives: MH Power Systems Europe Service GmbH an MHPSE subsidiary as from 1 August 2012 provides comprehensive solutions for fossil-fired power plants and its centerpiece steam generator. MH Power Systems Europe Service is an internationally operating company in energy generation and plant service. Its divisions comprising Boiler & Firing Technology, Flue Gas Cleaning, Mills & Turbine Service, Erection Work, Startup and Spare Parts Management ensure that fully developed services are available to upgrade power plant and firing systems of various designs and sizes for all conventional fuels. Evaporator module erection for a waste-to-energy (WTE) incinerator 32

33 for Tomorrow s Energy Manufacture of components for initial equipping, modification and spare parts More exacting requirements placed on emission control protect the environment. MH Power Systems Europe Service supplies fully developed and proven cleaning equipment such as electrostatic precipitator, fabric filter, scrubber and spray absorber with which to comprehensively comply with these requirements. Patented protective coatings of heating surfaces and pressurized system components ensure long service lives under corrosive and erosive conditions. Whether lignite or bituminous coal, internal or external products are involved, MH Power Systems Europe Service has an extensive know-how on coal mill optimization. Its portfolio is rounded off with spare parts, repairs and a comprehensive on-the-spot service. Turbine service is carried out under the premise of Maintaining output and availability. MH Power Systems Europe Service specialists can look back on a lengthy track record in the construction, commissioning and service of steam and gas turbines within the corporate group. As a 100 % subsidiary of MHPSE, MH Power Systems Europe Service can use the manufacturing facilities in the MHPSE Group together with those of associated partners. Spare Parts Management makes possible both rapid reactions and dependable solutions. Our Products 33

34 Extremely Resilient The Shield for Accelerated Boiler Service in use in Unit Q of the Boxberg power plant The material is incredibly thin yet extremely tear-resistant. Being referred to here is the several tons which a fabric devised by Mitsubishi Hitachi Power Systems Europe for inspection of utility steam generators can withstand. The Shield for Accelerated Boiler Service (SABS ) protects workers engaged, for instance, in inspection work or working on a fault inside a boiler from any falling slag lumps. The patented and TÜV-certified SABS system consists of a fabric coated with Kevlar and extends across the entire cross-section of the utility steam generator. It is mounted and moved on a support structure also developed by Mitsubishi Hitachi Power Systems Europe. In contrast to conventional solutions (scaffolding fitted along the boiler walls; tensioned safety nets), SABS provides not only more dependable protection but is also quicker to assemble and dismantle. It thus saves on both time and costs. Following exhaustive tests, SABS was effectively deployed for the first time in the inspection of Unit Q at the Boxberg power plant in mid Fabric spanning in the boiler took only 6 ½ hours. During unit cleaning, it intercepted up to three tons of material several times. MHPSE devised both the SABS fabric and the support structure 34

35 More Flexibility 1 Indirect firing DST Burner Cyclone Coal Dust Bunker Air Raw Coal Bunker 40 % Minimum Load % Ramp Rate Reduced wall thickness and increase in number of separators / headers 3 DST Burner: startup and partial load firing system in today s bituminous coal and crude lignite boilers 100% Biomass Capable Conveying Classifier Feeder Power Output +30 Δ% Plant Efficiency +3Δ% 5 +2 CO2 Emissions 0 Δ% % biomass capable 5 GT repowering G Fan Mill An appropriate configuration of existing technologies will not only significantly increase flexibility of a coal-fired power plant (also one that is optionally biomass-fueled) but also contribute from cost savings to greater plant competitiveness. The above scheme shows how to retrofit a conventional fossil-fueled power plant into a hybrid-fueled, high load and operationally flexible power plant one which assures a maximum utilization of renewable sources and production of additionally combined heat and power. By upgrading the firing system with an indirect firing capability 1 it is possible to reduce the minimum firing rate by approx. 15 %, if permitted by the burner control range. In conjunction with a retrofit utilizing DST Burners 3 the minimum firing rate can be lowered to about 10 % thanks to the burners wide control range. Below 10 % electrical power can be generated by using a connected gas turbine, as in the case of gas turbine repowering 5. Implementing an indirect firing system makes it possible to reach the designed ramp rates of newly build or older boilers; a reduction of thickness of thick walled components 2 clears the way for reaching a possible ramp rate of up to 10 % / min. Further ramp rate improvements come from gas turbine repower ing 5. Thus repowering / topping using gas turbines either in combined mode or recovery preheating makes it possible to improve flexibility by combining two different generation types in a smart way. It also enables the gross power output to be increased, plant efficiency enhanced and CO 2 emissions cut. The latter can also be achieved by using an indirect firing system 1 combined with DST Burners 3 burning (e. g.) woody biomass 4. Operation Improvements Up to 90 % of costly support fuel can be saved by switching very quickly to minimum stable coal / biomass load during start up. Mill operation for the indirect firing system preferable during off-peak times enhances efficiency due to constant mill speed in the optimum energetic range. Reducing auxiliary power consumption by introducing frequency speed control to induced and forced draught fans additionally elevates part load efficiency. Our Products 35

36 Our Know-How Whether it is new materials or energy storage technologies our experts are today researching into and developing the next generation of power plants. Our Kno

37 w-how

38 New Materials, Greater Efficiencies Mitsubishi Hitachi Power Systems Europe is researching into and developing new technologies for future power plant generations. To this end, the company, as plant constructor and specialist for thermal power plants, can look back on its extensive expertise and on a host of references. This helps our experts in the development and testing of new iron and nickel-based materials which are intended to make thermal power plants more efficient and flexible. Maximum precision for best quality: production in Meerane is already prepared for the 700 C power plant materials Conventional thermal power plants, such as those fired with bituminous coal, operate at a 600 C + operating temperature and come up with efficiencies of over 46 %. It is chiefly the attainable steam temperatures and pressures which are decisive for power plant efficiency. Raising the temperature to 700 C and having a 350 bar pressure could, for instance, lead to a 50 % efficiency as against the 38 % German average. This development target is referred to as the 700 C power plant in professional circles. However, its assumption is one of new materials given the fact that conventional heat-resistant steels can only be used up to approx. 600 C. That is why Mitsubishi Hitachi Power Systems Europe together with material and pipe producers as well as power plant operators are researching into the development and testing of iron and nickel-based materials. At the same time, these new materials need to reliably withstand all the mechanical and chemical stresses taking place at higher temperatures. Tomorrow s thermal power plant needs to achieve both a preferably high efficiency and substantially shorter reaction times in view of power being increasingly supplied from renewables such as from wind farms or photo voltaic systems. These reaction times necessitate a more rapid plant startup and shutdown which, in turn, can be brought about by developing design techniques and using new iron and nickel-based materials. Today s conventional designs would result, in particular, in a premature failure of thick-walled components. These ambitious development targets are being pursued in a Group global research network and in close cooperation with industry and university associates To this end, components, such as superheaters, piping and other system parts, have, for example, been made of newly-devised materials and installed in various test cycles. Final evaluation of component and material reaction is established by means of highlymodern examination techniques in both our own laboratory and in those of our associates. 38

39 Energy Storage: Liquid Air Energy Storage (LAES) For energy storage purposes, LAES firstly involves air being compressed and then cooled to the extent that the initially gaseous air proceeds into the liquid aggregate state. The liquefied air is then stored. If the need for energy rises in the power grid, a pump brings the liquid air to a higher pressure which is then evaporated. The pressurized gaseous air is heated and drives highly efficient gas turbines and expanders for the generation of electricity. No particular geological requirements on the site come from LAES so ruling out lengthy, complex approval procedures. Moreover, the expectation is for relatively short construction and lead times thus opening up the prospect of a rapid implementation of the technology. The required components represent well-developed uniform processes which for many years now have been deployed in the process / power plant industries. Only minor modifications are needed to adapt them to the LAES system. In addition, its integration into an existing power plant or industrial site would mean having available the required grid and gas infrastructure. The system can also be run as a backup gas power plant to the exclusion of energy storage and with an efficiency of up to 40 %. Conditional upon a number of process parameters, calculated storage efficiency is 65 % and over and thus comparable with the efficiencies of pump storage power stations. Process storage efficiency can also be raised further given the availability of industrial waste heat (from surrounding power plants) and / or spent cool air (LNG terminal). LAES-PROCESS Air Waste heat Heat storage (water) Heat use, CHP Flue gas M Back-up power production Air liquefaction Expander Gas turbine G Electricity Electricity Cold storage Evaporation Natural gas Liquid air Source: RWE Our Know-How 39

40 Energy Storage: Power-to-Gas (PtG) Together with associates from the process industry, Mitsubishi Hitachi Power Systems Europe is developing a process for generating synthetic natural gas (SNG) from carbon dioxide which arises in industrial or power plants. In a Power-to-Gas process (PtG), CO 2 is converted into a valuable fuel (methane or methanol) which can be used both in industry / transport and in households. To this end, oxygen (O 2 ) and hydrogen (H 2 ) are produced with excess current from water through electrolysis. Hydrogen and carbon dioxide are then the initial substances for both the production of methane and / or methanol and for manufacturing other high-grade products. The oxygen can also be additionally used in the process industry. The PtG concepts has a number of benefits to offer. On the one hand, surplus energy from renewable sources (e.g. wind farms, photo voltaic systems) can be effectively stored for a long period. On the other hand, PtG is considered to be a promising technique in reducing greenhouse gas emissions from the process / energy industries. As such, this process is a very promising alternative to the geological storage of CO 2. In addition, the fuels can be transported with the aid of the existing infrastructure (e.g. pipelines). Thus Power-to-Gas represents a vital, key technology in integrating renewable energies in a sustainable economy. POWER-TO-GAS (PTG): TRANSFORMATION OF CO 2 INTO CH 4 / REPLACEMENT OF NATURAL GAS WITH SNG Basis CO 2 CO 2 CO 2 CO 2 Raw materials Fuel Industry Long Distance Transport Gas PtG = SNG-Production CO 2 Electricity surplus Raw materials Fuel Industry H 2 CO 2 H 2 + CO 2 = SNG η el/th > 0,6 SNG 40

41 Globally Networked From higher efficiencies, tomorrow s energy storage systems to software online simulation of a power plant the know-how here is intensively exchanged across borders at the regular meetings of R & D staff. These GRDO Workshops (Global Research & Development Organization) represent one of the many examples of how our colleagues from Europe, Japan, South Africa and the USA are networked one to the other. Up-to-the-minute, ongoing market observations and findings from exchanges with customers and ministries from the various countries also find their way into the work and exchanges of R & D staff. Thus topics for the next-but-one technology are today being analyzed and prioritized on the basis of probable market regulating developments. Colleagues from highly diverse divisions / companies within the Group and / or parent company work together on complex assignments, such as with energy storage systems, and develop collective all-in solutions from Mitsubishi Hitachi Power Systems (thermal power plant construction and related turbo-machines up to batteries), Plant Technology (plant components) through to Hitachi-Mitsubishi-Hydro (HEP plants). Sales & Proposals specialists and Service staff also take part in these cross-divisional workshops in support of developments and refinements from customer-based suggestions. After all, the point of what our R & D colleagues research into today is to be rapidly turned, if possible, into commercially successful products. Staff from Europe, Japan and the USA regularly exchange their know-how Our Know-How 41

42 No Lack of References Mitsubishi Hitachi Power Systems Europe can look back on a long tradition in energy plant engineering. A selection of projects from the last few years testifies to the company s experience in the power plant field. Projects / Products of Mitsubishi Hitachi Power Systems Europe (Selection) since 2005 * Supply of utility steam generator, flue gas cleaning equipment, steam turbine / generator, civil engineering including cooling tower; overall plant layout ** Power Train = utility steam generator, flue gas cleaning equipment, steam turbine / generator including balance-of-plant equipment (excluding construction work, electrical engineering, instrumentation & control, external coal feeding etc.) *** in Consortium with Polimex-Mostostal Project Customer Product Capacity Ptolemais V Greece TERNA S.A. Power Train ** 1 x 660 MW 42 Kozienice Poland Maja / Solapur / Raghunathpur India Kusile South Africa Medupi South Africa Eemshaven Netherlands Rotterdam Netherlands Wilhelmshaven Maasvlakte Netherlands Moorburg Westfalen Datteln Neurath F & G Boxberg Walsum Gent Belgium Malmö Sweden Enea Turnkey power plant *** 1 x 1,075 MW NTPC Utility steam generator 6 x 660 MW ESKOM Utility steam generator 6 x 800 MW ESKOM Utility steam generator 6 x 800 MW RWE Flue gas cleaning 2 x 800 MW GDF Suez Power Train ** 1 x 790 MW GDF Suez Power Train ** 1 x 790 MW E.ON Utility steam generator 1 x 1,100 MW Vattenfall Utility steam generator 2 x 820 MW RWE Flue gas cleaning 2 x 800 MW E.ON Utility steam generator 1 x 1,100 MW RWE Utility steam generator 2 x 1,100 MW Vattenfall Utility steam generator 1 x 670 MW Evonik / EVN Turnkey power plant * 1 x 750 MW Electrabel E.ON Sverige Blast furnace gas utility steam generator Combined-cycle power plant 1 x 305 MWel 440 MWel 250 MWth As of: May 2013

43 Mitsubishi Hitachi Power Systems Europe references and those of its predecessor companies in the utility steam generator field also go back over many years. References for Mitsubishi Hitachi Power Systems Europe utility steam generators, (selection) Project Customer Fuel type Capacity Baoshan / Shanghai China Elbistan B Turkey Dezhou / Shandong China Iskenderun Turkey Niederaußem K Lippendorf R & S Boxberg Q Yang Liu Qing China Majuba South South Africa Schkopau A & B Altbach Rostock Staudinger 5 Megalopolis 4 Greece Baoshan Iron & Steel Co. Ltd. Turkish Electricity Generation & Transmission Corp. China National Import and Export Corp. (CNTIC) Siemens Project Ventures / STEAG consortium Blast furnace gas, Coke oven gas, Natural gas, LDO Lignite Bituminous coal, Anthracite Bituminous coal 1 x 350 MWel 4 x 360 MWel 2 x 660 MWel 2 x 660 MWel RWE Lignite 1 x 1,012 MWel VEAG Lignite 2 x 933 MWel VEAG Lignite 1 x 907 MWel CNTIC / HNPGC Electricity Supply Commission (ESCOM) Bituminous coal, Oil Bituminous coal 2 x 330 MWel 3 x 711 MWel 3 x 660 MWel VEBA Kraftwerke Ruhr AG Lignite 2 x 492 MWel Neckarwerke Bituminous coal 1 x 332 MWel KNG Kraftwerks- und Netzgesellschaft Bituminous coal 1 x 550 MWel PreußenElektra Bituminous coal 1 x 550 MWel Public Power Corporation Lignite 1 x 330 MWel Our Know-How 43

44 For many years now, Mitsubishi Hitachi Power Systems Europe (MHPSE) and MH Power Systems Europe Service have supplied combined-cycle plants for the energy industry. References for MHPSE and MH Power Systems Europe Service combined-cycle plants / heat-recovery boilers (selection) Project Customer Product Capacity Esenyurt Turkey Rüsselsheim Nowa Sarzyna Poland Debrecen Hungary Taweelah A1 UAE Matra Repowering Hungary Nyíregyháza Hungary Vasilikos Unit 4 Cyprus Öresundsverket Sweden Würzburg Bonn Kassel-Baunatal Saarbrücken Frankfurt Doğa Enerji Cons. Energie versorgung Opel Enron Debreceni Kombinált Ciklusú Erőmű Total Tractebel Emirates EPC Comp. Matra AG E.ON Hungary Electricity Authority of Cyprus E.ON Gasturbiner Sverige AB HKW Würzburg swb Energie und Wasser Energie- und Wasserversorgung Bonn / Rhein-Sieg GmbH VW Kassel GmbH Versorgungs- und Verkehrsgesellschaft Saarbrücken GmbH InfraServ GmbH & Co. Hoechst KG Combined-cycle plant Combined-cycle plant Combined-cycle plant Combined-cycle plant Combined-cycle plant Combined-cycle plant Combined-cycle plant Combined-cycle plant Combined-cycle plant Combined-cycle plant 1& 2 Heat-recovery boiler for combined-cycle plant Heat-recovery boiler for combined-cycle plant Heat-recovery boiler for combined-cycle plant Heat-recovery boiler for combined-cycle plant 180 MW 110 MW 117 MW 100 MW 1360 MW 50 MW 50 MW 220 MW 447 MW 45 MW 25 MW 25 MW 45 MW 33 MW 43 MW 44

45 MH Power Systems Europe Service provides individual solutions and services for steam generators and combustion systems for all conventional fuels. References from industrial and municipal energy generation customers (selection) Project Customer Fuel Capacity Bremen Derna / Tobruk Lybia El Tejar Spain Leuna Flensburg Obrenovac Serbia & Montenegro Vienna Austria Cilegon-Banten Indonesia Kuwait Kuwait Maasbracht Netherlands Linz Austria Stallingborough Great Britain Duisburg-Hamborn swb Erzeugung GmbH & Co. KG General Electricity Company of Libya (GECOL) Refuse-derived fuel Heavy oil 127 t / h steam 265 t / h steam Oleicola El Tejar S.L. Biomass 28 t / h steam STEAG GmbH Residue oils, Synthetic gases, Refinery gases, Natural gas 3 x 178 t / h steam 1 x 162 t / h steam Stadtwerke Flensburg Bituminous coal 3 x 150 t / h steam Electric Power Industry of Serbia (EPS) Fernwärme Wien GmbH PT Krakatau Steel Ministry of Electricity & Water (MEW) N.V. Elektriciteits-Produktiemaatschappij Zuid-Netherland (EPZ) voestalpine Stahl GmbH Millennium Inorganic Chemicals ThyssenKrupp Steel Lignite Domestic / industrial waste Heavy oil, natural gas Heavy oil, natural gas Natural gas Blast furnace / natural gas Chloric spent gas, natural gas Blast furnace gas, coke oven gas, natural gas 920 t / h steam 2 x 55 t / h steam 350 t / h steam 975 t / h steam 1,960 t / h steam 135 t / h steam 32 t / h steam 320 t / h steam Our Know-How 45

46 Impressions 46

47 Publisher Mitsubishi Hitachi Power Systems Europe GmbH Communication Schifferstraße Duisburg, Copyright Photos / Graphics Dirk Bannert Frank Elschner Rüdiger Fessel Stephanie Fortmann Mitsubishi Hitachi Power Systems Europe GmbH MH Power Systems Europe Service GmbH Philip Mostert Frank Preuß RWE Power Aktiengesellschaft Andreas Wenzel Layout / Overall Production Team Stiefelhagen Werbeagentur GmbH Our Know-How 47