The Bokpoort: CSP Continuous Operator Success Story Nandu D Bhula Chief Executive Officer Acwa Power Solafrica Bokpoort CSP South Africa
The Bokpoort CSP Busting Myths CSP with Adequate Storage: A new dawn in South Africa in Dispatchable, Load-Following, Renewables
Contents Bokpoort: Project Overview, Plant Layout, Technical Overview Thermal Storage and Base Load Capability Bokpoort Production Trends and Performance Records Review of Assumption on CSP in IRP 2010 South African CSP s: Capacity & Capability New Solar DNI Map supports CSPs Prospects for CSPs vs Old Coal Decommissioning Local Content & Knowledge prospects Proposed Way Ahead in CSP
The Overview of Bokpoort CSP Power Plant Project Overview, Layout, Capacity & Performance
Bokpoort CSP Project Overview Overview of Company and Project Founded: Ring-fenced project company effective June 2013 Site Location Site Coordinates: Latt. 28º44 26.96 S Long. 21º59 34.88 E Operational partner ACWA Power International: Saudi Arabian based with generation portfolio of 21GW and 2.4 million m 3 /day of desalinated water Total staff: ±1300 during Construction peak and 62 during Operations The site: Bokpoort Farm, 125km south-east of Upington (300 hectare Greenfield) Technology used: Concentrated solar thermal trough, with wet cooling and 1300MWht molten salt thermal energy storage (9.3hrs at 50MW) 20 year PPA with Eskom, through the Garona Substation located next to the site EPC - Project status Procurement and Suppliers: EPC consortium (Acciona, Sener, TSK, Crowie) 1 st Synchronisation 13 th November 2015 Early Operating Date 6 th February 2016 COD 19 th March 2016
Bokpoort CSP: Plant Layout CSP Parabolic Trough Technology with Storage Energy Source Rechargeable Battery Power Generation 50 MW Parabolic Trough CSP Plant: Wet Cooled Thermal Energy Storage = 9.3 hours at 50 MW (Largest in Africa) Offtaker is Eskom - Through the Garona Substation located next to the site 20 year PPA
Bokpoort CSP: Technical Overview Solar Field Eight Solar Fields - 180 Loops 48 Solar Collector Elements per Loop 8,640 SCEs Installed Flabeg Glass Mirrors 241,920 Mirrors 658,000 m2 of reflective surface SENER Trough Technology Schott Heat Collector Elements (25,920) HTF Dow Chemical (2,640 tons) Thermal Energy Storage 38,100 Tons of Salt (Potassium and Sodium Nitrate) Two Tanks Hot & Cold 40 m Diameter 14 m Height Bank Solar Energy during the day and release it at night or as needed Steam Generation Two Trains of Steam Generation Steam Supply 103.6 bara @380ºC (@ Turbine Inlet) Enthalpy 3028.7kJ/kg, Steam Flow 60.0 kg/s Siemens Steam Turbine SST-700 Single Reheat (HP, LP) Siemens Generator
50MW Daily Demand Profile Bokpoort CSP: Capability with Thermal Storage CSP + Storage = Base maybe not yet but Load Following (depending on size) Without Storage With Storage Load Following Winter Peak Summer Peak 30MW 06:00 09:00 12:00 15:00 18:00 21:00 24:00 03:00 Hours of the Day Note: Not to Scale for Illustration Purposes only
Daily Production MWh Daily Production Performance Trends 1000 900 800 700 600 500 400 300 200 100 0 161 hrs Continuous Operation - Low DNI - 25 Mar 13 hrs 111 hrs Continuous Operation Low DNI 18-Mar 19-Mar 20-Mar 21-Mar 22-Mar 23-Mar 24-Mar 25-Mar 26-Mar 27-Mar 28-Mar 29-Mar 30-Mar 31-Mar Continuous Operation 161hrs Continuous Operation 111hrs 9
Record Performance in 1st Month of Production Period: 18 March 2016 7:00am to 25 March 2016 1:00am Record: 161 hours of Operation Continuously (Base Load 100%) Load Factor: 76% (based on Energy Sent Out) *Possibly World Record performance in 1 st month of commercial production - TBC Period: 17 March 2016 8:00am to 31 March 2016 11:00pm Record: 310/352 hours of operation (88% of time on Load) Load Factor: 66% (based on Energy Sent Out) Continuous Operation 161hrs Continuous Operation 111hrs 10
The Review of CSPs Capacity & Capability Assumptions in IRP 2010, Future Prospects for CSP
Review of IRP 2010 updated version (Nov2013) New CSP modelled to only start around 2030 (based on learning rate and Scenarios) Big Gas Scenario has no further CSP consideration All Scenarios have dependency on OCGT s with even new plant planned as early as 2022 CSP Plant with storage can contribute significantly but allocation now will accelerate Learning Rate for LCOE to reduce rapidly already better then OCGT CSP Plant are modelled as Peaking options only Assumption regarding lead time and Load Factor related to CSP with Storage need review based on Bokpoort Experience OCGT CCGT Wind CSP, Parabolic Trough CSP, Central Receiver PV 3hrs 6hrs 9hrs 3hrs 6hrs 9hrs Fx tilt Rated Capacity (MW) 115 711 100 125 125 125 125 125 125 10 Life of Programme 30 30 20 30 30 30 30 30 30 25 Typical Load Factor 10% 50% 30% 31% 37% 43% 32% 40% 47% 19% Lead Time 2 3 4 4 4 4 4 4 4 2 CSP trough with 9hrs should be at least 60% LF and 3 years lead time Source: INTEGRATED RESOURCE PLAN FOR ELECTRICITY (IRP) 2010-2030 UPDATE REPORT 2013
South African CSPs Capacity and Capability 150 100 50 0 CSP Capacity Commissioning Schedule - Estimate KAX KHI BKP XIN ILG KTH RDN CSP1 CSP2 CSP3 Acwa Other Project Name: 2015 2016 2017 2018 2020 KaXu Solar One Khi Solar One Bokpoort Xina Solar One Ilanga I Kathu Solar Park Redstone Country: South Africa South Africa South Africa South Africa South Africa South Africa South Africa South Africa Location: Poffader Upington Groblershoop Pofadder Upington Kathu Postmasburg Upington Technology: Turbine Net Capacity: Parabolic trough Power tower Parabolic trough Parabolic trough Parabolic trough Parabolic trough Power tower CSP1 Power tower 100 50 50 100 100 100 100 150 Status: Operational Operational Operational Under construction Under development Under development Under development Preferred Bidder Stage Start Year: 2015 2016 2016 2017 2017 2018 2018 2019 Thermal Storage 2-tank indirect http://www.nrel.gov/csp/solarpaces/by_country_detail.cfm/country=za HP Steam Vessels 2-tank indirect 2-tank indirect Storage Capacity: Thermal Storage Saturated Molten salts Description: steam Peaking Grid Base/Load Peaking Peaking /Load Bokpoort Contribution CSP: A new dawn for Renewables Following South Africa acwapower.com Following 2-tank indirect 2-tank indirect 2-tank direct 2-tank direct 2.5 hours 2.5 hours 9.3 hours 5 hours 4.5 hours 4.5 hours 12 hours 7.5 hours Molten salts Molten salt Molten salt Molten salt Molten salt Molten salt Peaking /Load Following Base/Load Peaking Base Load Following
201 5 2016 2017 2018 2020 2020 2021 2022 2023 2024 2025 2026 2027 20 28 Prospects for CSP: Given Old Coal Decommissioning Food for Thought: Why not Swop Old Coal for New CSP (+ Adequate Storage) Alternatives Commodity dependent CSP Capacity Commissioning Schedule Estimate * CSP3 CSP2 CSP1 RDN KTH ILG XIN BKP KHI KAX 0 50 100 150 200 ** http://www.eskom.co.za/ir2015/pages/default.aspx **. Old Coal Fleet Capacity Decommissioning Schedule - Estimate -200-150 -100-50 0 * http://www.nrel.gov/csp/solarpaces/by_country_detail.cfm/country=za KMT9 KMT8 KMT7 KMT6 KMT5 KMT4 GVL6 GVL5 KMT3 KMT2 GVL4 KMT1 GVL3 GVL2 GVL1 CMD8 CMD7 CMD6 CMD5 CMD4 CMD3 CMD2 CMD1
New Solar Resource Maps in Support of CSPs By: Stellenbosch University, in cooperation with GeoSUN Africa and GeoModel Solar (April 2016) The highest DNI predicted in South Africa is now 3 200 kwh/m2 per annum in the Northern Cape. The accuracy-enhanced database shows DNI values higher, up to 10% in some areas, compared the previous database, positioning South Africa as an excellent candidate for CSP power stations
The Review of CSPs Local Content & Industry Contribution Local Content Bokpoort, Prospects with greater Allcoation
Bokpoort Local Content: Competence & Knowledge Local Spend Analysis Total Estimated local value add (in ZAR) - Approx R1.6 Billion Large portion of Local value add in Civil works: Concrete, Reinforcing steel, structure steel etc. Main SA manufacturers Turnmill (Gauteng) HTF Expansion/Overflow Vessels MEAPSA (Upington) Salt Tanks (Thermal Storage) Made SA (Gauteng) Torque Tubes, Pylons for Solar Field TRP SA (Cape Town) - Torque Tubes, Pylons for Solar Field Approximately 8160 tonnes of steel for all Torque Tubes Approximately 1200 tonnes of steel for all Pylons SA Manufacturing and Pre-Assembly Steam Turbine Foundations HTF Vessels HTF Vessel Foundations HTF Vessels Main SA Pre-Assemblers and On-site Assemblers Proimtu (Upington) HTF Solar field piping CAMETO (Upington) HCE Stainless steal piping Condusav (Cape Town) HP Power Block Piping Batz (On Site) Solar Collector Elements SCE Torque Tubes SCE Pre-Assembly Total Estimated training performed 100000 hours, Safety Training 20% Small Tools Use 20% Job Training & Skills Specific Training 60% On Scaffold Use, Foundation Erection, Welding Setup, Electrical Cable Pulling & Termination, Salt Tanks SCE Pylon Fabrication
Possibilities that CSPs bring for Increased Local Content 60% 40% 20% 0% Round 1 Round 2 Round 3 Round 4 SA Market 100MW/y SA Market +200MW/y SA Manufacturing Infrastructure CSP specific Civil / Cooling Tower Valves & Actuators Pressure Vessels Collector Structure Storage Tanks Piping Cabling Other Parabolic Mirrors / Heliostats Collector Structure Precision Tracking Systems Receiver Pipes / System Heat Transfer Fluid W/S Cycle Engineering 35-40% 60-65% If CSP Market is + 200MW/year CSP Market Size means Economies of Scale Repeatability (e.g. collector structure)
Possibilities that CSPs bring for Increased Local Content. We need to have a long term view on CSP with Adequate Storage in SA given capabilities proven by current CSP s in operation: 1. Only storable renewable energy with utility scale Peaking and Base Load/Load Following Capability 2. Flexibility in dispatch meets SA demand profile 3. SA is blessed with an enviable Solar Resource 4. Short lead times for quick deployment possibility 5. Extremely competitive (LCOE Learning rate Round 1-4.5) 6. Existing SA manufacturing infrastructure complements CSP 7. Potential to increase local content whilst growing local competence and knowledge 8. Greater Socio-economic development for local communities
Thank you The Current discussions regarding alternatives for base and load following (mid-merit) grid requirements need to include the possibility of CSP with adequately sized Storage as a viable competitor. These plants are poised as Bokpoort CSP: significant A new dawn contributors for Renewables in to South the Africa technology mix going forward.