Advanced Power Plants Coal Fired Steam Power Plant

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1 Advanced Power Plants Coal Fired Steam Power Plant Prof. Dr.-Ing. H. Spliethoff Lehrstuhl für Energiesysteme

2 Content 1. Situation today 2. Efficiency: achievements and outlook 3. Future discussion of the energy concept 4. Flexibility of power plants

3 1. Today Requirements: today (Germany) Today (2010): Share of renewables 16 %, Wind 26 GW, PV 17 GW Source: Spliethoff: et. al, CIT 2011

4 1. Today Power Plant Capacity and Production (2010) Capacity [%] Total: 168 GW Production [%] Total: 621 TWh : nuclear coal domestic gas oil pump storage 3% others* renewables 33% 3% 3% 14% 13% 31% 3% 1% 1% 14% 16% 23% 42% full load hours (calculated) Total: 1825 h/a (21%) Coal 5000 h/a (58 %) Economic and environmental motivation for an efficiency increase Source: Spliethoff: et. al, CIT 2011

5 2. Efficiency Possibilities to increase efficiency Technische Universität München Increasing the average temperature of heat addition Decreasing the average temperature of heat removal Reducing losses Design Operation Part load Start-up, shut-down

6 2. Efficiency Temperature of heat addition Live steam pressure and temperature: 200 bar/540 C/540 C 300 bar/ 600 C/620 C Δη =2,5 % Double RH Feed water preheating: k 0,7 % Relative change in efficiency [%] 12% 10% 8% 6% 4% 2% 0% 350 bar 300 bar 250 bar 190 bar Live steam temperature =Reheat temperature [ C] Source: Spliethoff: Power Generation from Solid Fuels, Springer 2010

7 2. Efficiency Limitations by materials Membrane wall Pipes Headers MS-Pressure MS-Temperature RH-Temperature Source: Alstom

8 2. Efficiency Temp. heat extraction Wet Cooling Technische Universität München Kondensattemperatur temperature = 36 C C Condensate Warmwasser- water temperature = 28 34,5 C C Cold Kaltwassertemperatur water temperature = C C Wet-bulb Feuchtluft- temperature = 6.6 6,6 C Kondensatorgrädigkeit difference of condenser terminal temperature Kühlzonenbreite cooling range Kühlgrenzabstand Approach Trockenluft- dry air temperature = 8,5 8.5 C Reduction of condenser temperature by 10 K 1,2 % lowest possible condensation temperature: wet bulb or wet air temperature difference is caused by: terminal temperature difference of the condenser cooling range (= warm-up margin) approach Economic optimization 2-8

9 3. Efficiency Losses Steam generator losses Turbine losses Pipe losses Generator losses Auxiliary power demand

10 2. Efficiency Steam Generator Losses Steam Generator Losses Old Plant (1980) Modern Plant air ratio 1,3 1,15 exhaust temperature 130 C 110 C exhaust losses 5,3 % 3,8 % radiation losses steam generator 0,25 % 0,3 % losses through unused fuel flue ash 0,2 % < 0,3 % coarse ash 0,1 % < 0,2 % sensible heat flue ash 0,02 % 0,03 % coarse ash 0,04 % 0,04 % total 5,9 % 4,6 % Source: Spliethoff: Power Generation from Solid Fuels, Springer 2010

11 Isentropic turbine efficiency [%] Technische Universität München 3. Efficiency Isentropic turbine efficiency Year Werte Billotet aus 1995 Diagramm Add.values Zusatzwerte

12 2. Efficiency Brown coal External Predrying superheated steam ~150 C brown coal condensation heat water carrier gas mill dryer pre-drying at low temperatures flue gas coal dust and carrier gas External pre-drying leads to efficiencies comparable to hard coal, because Steam generator losses are limited (seperated vapors removal) The drying medium is used at low temperatures Efficiency is higher than that of hard coal, if the condensation heat of vapors is used Improvement by 5 % is possible

13 2. Efficiency Reference power plant Technische Universität München

14 2. Efficiency Data Hard Coal Steam Power Plants Technische Universität München Circuit Zolling Staudinger Rostock NRW R&D Thermie R&D Thermie initial Operation Projekt Projekt Projekt net Output [MW] LS-pressure [bar] LS-temperature [ C] RH-temperature [ C] / 720 RH-pressure [bar] / 23,5 condensation pressure [bar] 0,04 0,038/0,052 0,027/0,033 0,045 0,045 0,045 cooling cooling tower/river cooling tower cooling tower/ocean cooling tower cooling tower cooling tower feed water temperature [ C] number of preheaters efficiency [%] 41,3 42,7 43,8 45,9 48,7 50,1

15 Efficiency Technische Universität München 2. Efficiency Average operational efficiency best point <2004 full load 6000 >2004 best point full load best point <1990 full load 5000 < > < Capacity (MWe netto)) data from Theis 2005

16 electricity [TWh] Technische Universität München 3. Future Goals of the energy concept year Source: Spliethoff et. al, CIT 2011 import/export conventional renewable energies consumption of electricity

17 3. Future Goals Energy Concept Power generation D 637 TWh % % Share of coal 43 % 37 % 30 % 20 % 18 % Full load operation hours Bit. C. Brown C

18 4. Flexibility Requirements: tomorrow (Germany) Morgen Tomorrow (2020) Installed capacity: Wind 46 GW PV 50 GW Constant consumption Tomorrow (xxxx) Installed capacity: Wind 75 GW 50 GW PV Requirement for low minimum load Source: Spliethoff: et. al, CIT 2011

19 gradient [MW/15min] capacity [MW] Technische Universität München 3. Flexibility Change of power from Renewables 2020 Forcast of a winter day ( ): time [h] 46 GW Wind 50 GW PV time [h] Requirement for fast load change and start-up Source: Spliethoff: et. al, CIT 2011

20 load [%] Technische Universität München 4. Flexibility Load change capability time [min] dry lignite technology hard coal CCP nuclear power plant Data from Lambertz, RWE

21 4. Flexibility Load range Minimum load Coal Load range 30/40 % -100 % Firing stability determines minimum load Requirement: safe operation in case of a mill failure Minimim load Pure coal firing: % 25 % oil/ ng support: 25 % Change of once-through to circulation results in limitations Brown coal appr.50 %, Dried brown coal comparible to hard coal

22 4. Flexibiliy Load Change Capability Secondary Control Only by fuel mass flow Delay of the mill (Storage of the mill) Pressure increase of boiler (Gliding pressure) Big load changes > 20 % 3-6 % / min Limit by turbine inlet temp. 1-2 k/min Small load changes < 20 % 1-2 % / min

23 4. Flexibility Start-up, Shut-down Old Coal Plant New Coal Plant CC new Hot start up (8h) 2 h 1-2 h 0,5-1 h Warm start-up (48 h) 4-5 h 3 h 1-1,5 h Cold start-up (72 h) 4 h 2-3 h

24 Conclusions for coal fired power plants - Substantial efficiency increase in the past - Flexibility requirements - Minimum load and load change capability comparable to CC - Start-up slower - Full load operation hours of coal fired pp will decrease Economic conflict: efficiency - Coal: Gasification concepts become more attractive

25 Thank You for Your Attention

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