Bełchatów - Retrofitting the EU s Largest Power Plant Site Dr. Christian Storm, Dr. Georg Gasteiger, Dr. Bernhard Pinkert, Frank Adamczyk, Krzysztof Matyskiewicz 31.10.2012
Worldwide new trends in energy strategy Page 2 The giant nuclear accident in Fukushima caused fundamental changes in the energy strategy and especially the power plant construction program of the western world. Nuclear phase-out program in place Impact on global energy mix in short term gas and renewables gain importance Revival of coal in Europe and USA as reliable energy source? With CCS? Majority of investment additionally in renewable energy for gas and coal fired power plants However: The focus will be on clean coal technology with high efficiency! And CCS? Source: The Mcilvaine Company, March 2011
Age structure of power plants in the EU 27 Page 3 Year of bringing into service Lignite Nuclear Coal Gas/Oil Over 65% are older than 20 years and thus in the second half of their lifecycle Over 35% are older than 30 years Source: IEA, VGB, RWE Power Installed output (MW)
Retrofitting of coal fired power plants Page 4 The European power plant capacity needs to be replaced or modernized. Due to the nuclear phase-out we have to be fast! Renewables can not replace the whole capacity due to transportation, storage, quantity (biomass) and volatility (solar, wind). Especially in Germany there is a strong opposition against new build of large-scale power plants. As long as there is no political and corporate understanding / agreement, one possible solution is the retrofitting of older coal fired power plants. The Bilfinger Power Systems Group set an example at Bełchatów power plant in Poland. The group company Babcock Borsig Steinmüller was retrofitting the boilers 3 to 5 until 2011 and will modernize the boilers 7 to 12 until 2016.
Goals of the complex modernisation programme Page 5 Step 1 Extending useful life time Increasing availability Step 2 Reducing emissions Complying with international environmental standards Step 3 Boosting capacity Increasing plant efficiency Step 4 Cutting fuel consumption Extending the power station s operational life time
Milestones in the history of Bełchatów power station 1981 First unit connected to the grid 1988 Blocks 1 to 12 are online with a capacity of 360 MW each 1994 Modernisation of the turbine low-pressure parts boosts unit capacity to 370 MW 2010 Capacity of unit 3 to 5 raised to 380 MW via modernisation work involving highand medium-pressure parts in the turbine and steam generator 2011 Capacity of Block 6 is likewise boosted to 380 MW Commercial operation of new built unit with a capacity of 833 MW 2014 Scheduled completion of modernisation work on units 7 to 12 Page 6 Fuels used Kleszczów raw brown coal Szczerzów raw brown coal Złoczew raw brown coal ( 2035?) Caloric heating value 6.5 8.7 MJ/kg Water content 47 56% Ash content 9.7 18.4%
Optimising circulation process Example of Unit 5 Page 7 Boosting the steam generator efficiency Raising the SH and RH temperatures Boosting the feed water temperature by installing HPpreheater 3 Modernisation HP and MP turbine parts
Adjustment of the process parameters Page 8 Original Modernization Design Unit 3 Unit 4 Unit 5 Unit 7-12 Year of Contract 2005 2007 2009 2011 HP Mass Flow t/h 1090 1,100 1,100 1,125 1,125 HP Steam Temperature C 540 550 550 570 560 Reheated Steam Temperature C 540 570 570 570 570 Boiler Feedwater Temperature C 255 255 255 275 255 HP Steam Pressure MPa 17.7 18.0 18.0 18.5 18,7 Gross Efficiency % 38.1 39.3 39.3 40.1 39,4 Lower Calorific Value MJ/kg 7.75 7.75 7.75 7.75 7,75 Fuel Mass Flow t/h 442 449 449 431 450 Generated Heat MW 852 870 870 860 874 Combustion Power MW 946 960 960 948 965 Generator Output MW 360 380 380 380 380
Content of the complex modernisation programme Page 9 Steam generator Pressure part (eco, evaporisor, superheater, HP- & RH piping, etc.) Furnace (burner, burnout grate & over-fire air system) Process control Turbine Replacement of high- and medium-pressure parts Safety and control valves Auxiliary installations (feed pumps & high-pressure preheaters) Pipelines High-pressure piping Reheater piping Auxiliary installations Steam and regenerative air preheaters Electrostatic precepitator (EPC) Flue gas desulphurisation Heat recovery system
Modernising the steam generator Extending its lifetime and increasing steam temperatures Page 10 Eco heating surface replacing the pipe elbows and adjusting the heating surface Enlarging the SH1 superheater Adjusting the RH1 reheater surface Replacing the final superheater Evaporiser separation and conversion of evaporiser wall into superheater HP0 Evaporiser replacement of hopper, elbows for burners and over-fire air systems Replacement of connection pipes and valves
Modernising the steam generator Emission-reduction measures Page 11 Installing over-fire air level 2 (10 lances) Installing over-fire air level 1 (18 double nozzles) Installing a new coal dust burner Replacing the coal dust ducts Replacing the classifiers Adjusting mill housing Replacing the burnout grate (2 opposed travelling grates)
Burners and over-fire air lances (OFA2) Page 12 Unit 3 coal dust burner Over-fire air lances (OFA2)
Heating surface thermal absorption [MW] Operating results Thermal design and steam temperatures Thermal absorption of heating surfaces Comparing specification and operating figures at 380 MW = 100% load SH part load temperatures Page 13 Operation data 30.05.08 380 MW 140 120 100 80 60 40 83,7 76,1 84,6 43,5 80,1 93,4 108,5 101,1 63,3 41,6 101,8 115,8 55,6 41,0 Project Readings RH part load temperatures 20 0 Eco P0/P1A P1B P3 P4 M1 M2
Furnace optimisation Example: Temperature Distribution with Iso-Surface 1200 C Page 15 RW RW VW VW Temperature [ C] OFA 2 Flue gas recirculation duct OFA 1 Burners
Furnace optimisation Example: Oxygen Distribution with Iso-Surface 6 % Page 16 Oxygen [vol.-%, dry]
Optimising the furnace Movement of over-fire air Page 17 Over-fire air 1 Over-fire air 2 Results of optimisation: Up to a load of approx. 70% over-fire air level 1 dominates At higher loads and with falling residential time, the use of over-fire air level 2 is increasingly necessary Conclusion: Given the existing combustion chamber dimensions and resulting residential time, installing lances in the superheater area as over-fire air level 2 was vitally necessary.
Results of the furnace optimisation Unit capacity and half-hour average CO and NOx values in Unit 5 Page 18 The required emission levels were met throughout the load area NOx average value for day: 171 mg/nm³ CO average value for day: 144 mg/nm³
Heat Recovery System (ECOGAVO) Retrofit of Unit 5 & 6 Page 19 Clean gas reheater Water cycle Bypass FGD Flue gas cooler Clean gas from ESP Stack FGD with flue gas cooler and reheater Reheating of Clean Gas by flue gas cooling, instead of mixture with combustion air Less fouling in clean gas duct area Pre-heated combustion air can be used in the boiler Increase of boiler efficiency
Heat Recovery System (ECOGAVO) Retrofit of Unit 5 & 6 Page 20 Performance data of Heat Recovery System Flue gas volume flow 1,7 Mio. Nm³/h Flue gas inlet temperature 160 C Clean gas reheating Pressure drop (total) Heat duty (per Unit) 10 K 3 mbar 8 MW Assembly of Heat Exchanger Module into the casing
Results of the complex modernisation Reduction of fuel consumption Page 21 The modernisation means that fuel consumption between now and 2045 has been cut by 70.9 million tons, increasing the useful live time of the open-cast mines and power station by approx. 1.5 years!
Summary Page 22 Unit capacity increased from 370 MW in 2005 to 380 MW Emissions reduced to match international environmental standards Lifetime extention by a further 200,000 h operating hours Unit efficiency increased by approx. 2% (units 5 and 6) 71-million-ton reduction in lignite consumption increases operating lifetimes of the open-cast mines and power station by approx. 1.5 years
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