bełchatów - retrofitting the eu’s largest power plant -babcock borsig steinmüller gmbh

8/12/2019 Bechatw - Retrofitting the EUs Largest Power Plant -Babcock Borsig Steinmller GmbH

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Bechatw- Retrofitting the EUs Largest Power Plant Site

Dr. Christian Storm, Dr. Georg Gasteiger, Dr. Bernhard Pinkert, Frank Adamczyk, Krzysztof Matyskiewicz

Babcock Borsig Steinmller GmbH

ICCI 2013, Istanbul, 24.04.2013


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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 (US) and

renewables (EU) gain importance

Revival of coal in Europe and USA as

reliable energy source?

With CCS?

Majority of investment in

renewable energy

However: There is still a focus on

clean coal technology with

high efficiency!

And CCS?Source:

The Mcilvaine Company, March 2011

Worldwide New Trends in Energy StrategyBabcock Borsig Steinmller GmbH


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Source: IEA, VGB, RWE Power

Over 65% are

older than 20

years and thus

in the second

half of theirlifecycle

Over 35% areolder than 30

years

Lignite

Nuclear

Coal

Gas/Oil

Installed output (MW)

Year of bringing into service

Age Structure of Power Plants in the EU 27Babcock Borsig Steinmller GmbH


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Page 4Retrofitting of Coal Fired Power Plants

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 Bechatwpower plant in Poland.

The group company Babcock Borsig Steinmllerwas retrofitting the boilers 3 to 5 until 2011

and will modernize the boilers 7 to 12 until 2016.



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Page 5Goals of the Complex Modernisation Programme

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 stations operational life time



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1981 First unit connected to the grid

1988 Blocks 1 to 12 are online with a capacity of 360 MW each1994 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 high-

and 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

Fuels used

Kleszczwlignite

Szczerzwlignite

Zoczewlignite (after approx. 2035)

Caloric heating value 6.5 8.7 MJ/kg

Water content 47 56%

Ash content 9.7 18.4%

Milestones in the History of BechatwPower StationBabcock Borsig Steinmller GmbH


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Modernisation

HP and MP

turbine parts

Raising the SH andRH temperatures

Boosting the feed

water temperature by

installing HP-

preheater 3

Boosting the steamgenerator efficiency

Optimising Circulation Process

Example of Unit 5



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Page 8Adjustment of the Process Parameters

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



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Page 9Content of the Complex Modernisation Programme

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 preheatersElectrostatic precepitator (EPC)Flue gas desulphurisationHeat recovery system



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Enlarging the SH1 superheater

Adjusting the RH1 reheater surface

Replacing the final superheater

Evaporiser separation and conversion

of evaporiser wall into superheater

HP0

Eco heating surfacereplacing the

pipe elbows and adjusting the heating

surface

Evaporiserreplacement of hopper,

elbows for burners and over-fire air

systems

Replacement of connection pipes and

valves

Modernising the Steam Generator

Extending its lifetime and increasing Steam Temperatures



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Adjusting mill housing

Replacing the classifiers

Replacing the coal dust ducts

Installing a new coal dust burner

Installing over-fire air level 1

(18 double nozzles)

Installing over-fire air level 2

(10 lances)

Replacing the burnout grate

(2 opposed travelling grates)

Modernising the Steam Generator

Emission-reduction Measures



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Unit 3 coal dust burner Over-fire air lances (OFA2)

Burners and Over-Fire Air Lances (OFA2)Babcock Borsig Steinmller GmbH


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Thermal absorption of heating surfaces

Comparing specification and operating figures

at 380 MW = 100% load

SH temperatures vs. steam generator load

RH temperatures vs. steam generator load

76,1

84,680,1

108,5

63,3

101,8

55,6

83,7

43,5

93,4

101,1

41,6

115,8

41,0

0

20

40

60

80

100

120

140

Eco P0/P1A P1B P3 P4 M1 M2Heatingsurfacethermalabsorption[MW]

Operation data 30.05.08380 MW

Project

Readings

Operating Results

Thermal Design and Steam Temperatures



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Furnace Optimisation

Example: Single Burner Simulation

Upper Air / Lower Air

Core Air

Coal

Middle Air

Cooling Air

Velocity Profile



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Temperature

[C]


Example: Temperature Distribution with Iso-Surface 1200 C

Flue gas recirculation duct

OFA 1

Burners

VW

RW

VW

RW

OFA 2



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Example: Oxygen Distribution with Iso-Surface 6 %

Oxygen

[vol.-%, dry]



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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.

Optimising the Furnace

Control of Over-Fire AirBabcock Borsig Steinmller GmbH


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The required emission levels were met throughout the load area

NOx average value for day: 171 mg/Nm (limit: 200 mg/Nm)

CO average value for day: 144 mg/Nm (limit: 200 mg/Nm)

Results of the Furnace Optimisation

Unit Capacity and half-hour Average CO and NOx Values in Unit 5



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Heat Recovery System (ECOGAVO)

Retrofit of Unit 5 & 6

Clean gas reheater

Water cycle

Flue gas

cooler

Bypass

Clean gas

from ESPFGD Stack

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

FGD with flue gas cooler and reheater



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Heat Recovery System (ECOGAVO)

Retrofit of Unit 5 & 6

Assembly of Heat Exchanger Module

into the casing

Performance data of Heat Recovery System

Flue gas volume flow 1,7 Mio. Nm/h

Flue gas inlet temperature 160C

Clean gas reheating 10 K

Pressure drop (total) 3 mbar

Heat duty (per Unit) 8 MW



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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!

Results of the Complex Modernisation

Reduction of Fuel Consumption



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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

SummaryBabcock Borsig Steinmller GmbH


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bełchatów - retrofitting the eu’s largest power plant -babcock borsig steinmüller gmbh

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