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Modernization of Combustion Systems

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Hitachi Power Europe

Technology Leader with Excellent References

Whether as a plant constructor or as a supplier of key components, Hitachi Power Europe

GmbH (HPE) is one of the technology and market leaders in fossil-fired power plants.

The company – a subsidiary of Hitachi, Ltd. – has its head offices in Duisburg. HPE designs

and builds not only power plants but also supplies all the key components such as utility

steam generators, environmental engineering equipment, turbines and pulverizers. In so

doing, HPE can turn back to a track record going back over many years, an extensive list

of references and to the outstanding know-how of its workforce. Within the Hitachi Group,

HPE is responsible for the markets in Europe, Africa, Russia (incl. Belarus) and India.

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Contents

Modernization of Combustion Systems 3

Key for a Successful Rehabilitation Project 4

Competence in Firing Systems 8

Our Own Manufacturing Facilities 9

Success Products 10

Solutions to Increasing Plant Flexibility 18

Rehabilitations – References 20

Inspire the Next 22

Hitachi Power Europe GmbH, Duisburg

Babcock Fertigungszentrum GmbH, Oberhausen

BGR Boilers Private Ltd., Chennai

Donges SteelTec GmbH, Darmstadt

5 Hitachi Power Africa (Pty) Ltd., Johannesburg

6 Meeraner Dampfkesselbau GmbH, Meerane


Modernization of Combustion Systems

Low Emission and Flexibility Issues

Present developments on the energy market are enlarging the wide portfolio of moderniza-

tion schemes by flexibility issues as, in the future, conventional power plants will be facing

competition for power production during those limited and fluctuating time cycles caused

by increased production from renewable energies.

Modernization measures usually comprise

■■ Increase of availability, efficiency and performance

■■ Optimization of combustion process, reduction of emissions

■■ Lifetime extensions

This is extended nowadays by flexibility issues like

■■ Load ramp enhancement

■■ Startup / low load optimization

■■ Fuel alternatives (fuel change, biomass, pre-dried pulverized fuel, skip of oil / gas)

■■ Pulverized fuel storage

Complex measures are required to operate existing units economically under these new

market conditions. Here modernization of the firing system plays a key role. HPE, as a

modern technology supplier with many years of competence in the worldwide new-built

and rehabilitation business, is on hand both for classic rehabilitation and the new tasks.

* See also HPE brochure: Solid Fuel Firing Systems and Components

in combination with a wealth of experience with other components like fans, air heaters, soot blowers and pumps from ongoing contracts

Combustion solu-tions using HPE’s innovative swirl burner technology for all fuels

Milling technology (lignite, bituminous coal)

Coal feeder and deashing technology

Pressure parts, ductworks

For all modernization work involving the combustion process, HPE delivers – based on its own technology and

key components * – the required advanced

4

Key for a Successful Rehabilitation Project

Own Engineering and Technology

Within the last 30 years HPE has gained experience from more than 550 modernization

schemes, rehabilitation work and studies worldwide and thus HPE is your partner for

challenging rehabilitation undertakings for the entire boiler.

HPE’s primary interest is the engineering driven concept of design for best solutions as

well as supplying its own key components – with labor intensive manufacturing as well

as dismantling / erection work to be executed by local partners (advised / supervised by HPE

specialists) or by power plant staff.

HPE offers advantages in technology and competence for your project

■■ Experienced acknowledged specialists and contact partners

■■ Own product development (patents), own software development –

partly in Hitachi wide cooperation

■■ Active participation (project leader) in essential research activities

■■ Parametric design, supported by up-to-date tools (PDS, ProE)

■■ Accredited own laboratory for coal, ash and damage analysis

■■ Experience gained from worldwide commissioning and operation of ongoing plants

■■ CFD simulation (Computational Fluid Dynamic calculations) to support design concepts

Overall Rehabilitation Performance Increase 42%

Upgrade of Combustion System NOX Reduction 19%

Increase of Efficiency 19% and Availability

Redesign of Firing System 10% Fuel Change

Lifetime Extension / 10% Others


Co-operative Approach

We are your partner for complex rehabilitation work in which – through process optimiza-

tion of plants and components – remarkable economic and ecological improvements are

gained. This can even come from a simple design solution supported by CFD simulation

calculations. HPE has already designed the most effective of concepts in instances of

where the OEM’s solutions have failed.

Upfront of a potential rehabilitation HPE offers engineering concepts for a common stepwise

approach:

The benefits

■■ HPE’s proven cost- and time efficient way of proceeding for identification of

potential measures

■■ Development of effective measures for complete rehabilitation to schedule

■■ Risk limitation due to solutions supported by Simulation Calculations (CFD)

Should you be interested, we are more than ready to discuss these steps in detail with you.

Time and Budget Saving Procedure for a Solution Demonstration

Your detailed plant / component expertise including knowledge about damage and malfunctions as well as your draft ideas for improvement.

Our experts’ knowledge about solutions and expe-rience obtained in similar applications worldwide. *

* Example: Similar grinding / firing topics in the Balkans and Australia

+ Bundled “hand in hand” knowledge as best basis for the project, from the first idea up to successful completion.

==

Detailed Study

Common Investigation for Problem Analysis

Basis of the Ultimate Solution

HPE REviEW of plant data

ExPERiEnCE ExCHanGE with plant staff

SiTE invESTiGaTiOn Mill measurement program and coal /ash analysis by HPE

UPGRaDE COnCEPT (by HPE) supported by CFD simulation with budget indication

UPGRaDE OF PilOT EqUiPMEnT for demonstration purposes

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Key for a Successful Rehabilitation Project

CFD Simulation Calculations

CFD programs can be applied by many users. However without validation by reality and

associated calibration, the results may not serve as a reliable design support.

For HPE these programs are essential as valuable tools in supporting concept developments.

For this reason, HPE is very much interested in permanently calibrating those programs for

simulation of fluid dynamics and emissions from its own know-how and latest HPE supplier

experience. The aim of this validation is to have a reliable tool during the design stage to

simulate the reality for even complex issues.

By application of these calibrated CFD programs, verification is undertaken of HPE’s engi-

neered solution for optimization of the components or complete plants.

■■ Hitachi’s own test facilities

■■ Intensive research and

development activities

■■ HPE’s own laboratory

(accredited DIN EN ISO / IEC 17025)

■■ HPE’s own commissioning

experts / activities

■■ Testing of research findings

in utility plants

■■ Operation experience from

utility plants

■■ Many years of Babcock / Hitachi

know-how

■■ Hitachi’s internal (German-Japan)

experience exchange for

continuous optimization and

development of the latest calculation

methods

Feedback from Reality


Visualization of Improvements

Thus for potential rehabilitation purposes, both the existing situation with related problems

as well as the future situation can be demonstrated after implementation of HPE’s concept

from an impressive visual comparison – this is done during the early stage without

affecting the plant – and under reasonable costs.

latest Developments

Meanwhile the development of the simulation programs has been extended with the result that

■■ Dynamics of ignition and combustion process at burners as well as

■■ Location and rate of wear, e. g. in PF ducts

can be impressively simulated; the latter being an important forecasting element for the service

and maintenance department.

This procedure from CFD simulation support has proven to be successful. Based on key

boiler data and parameters, coal / ash analysis as well as information about malfunction,

studies enable HPE to evaluate the intended rehabilitation measures.

In line with the given project task, HPE defines the required scope of measures and related

guarantee values and evaluates budget requirements.

Existing Situation HPE Upgrade Concept

Same task for similar mills (Serbia /Australia)

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Competence in Firing Systems

Main Driver for Plant Improvement

Process optimization of the combustion process together with the most advanced grinding

and firing equipment allow HPE to offer efficient rehabilitation work at reasonable costs.

Solutions for burners, grinding equipment as well as the furnace – which have been refined

for over 10 years now – are optimized using the above simulation calculations. Typical firing

problems which can lead to inefficient operations, unnecessary emissions or even plant

damage are the following:

■■ Unstable coal firing

■■ Support firing

■■ Over-high emissions (NOX, CO)

■■ Problems with fuel change-overs

■■ Incomplete combustion (high UBC values)

■■ Over-high furnace end temperature (FEGT)

■■ Slagging / fouling problems

■■ Furnace wall corrosion

As a rule, in order to reach optimization targets on a sustainable basis, all related systems like

grinding equipment, burners and the furnace need to be considered as a whole. Optimized

grinding is the key to successful firing rehabilitation. Related mill measurements on existing

plants provide valuable information on the optimization potential. Improved grinding perfor-

mance in combination with HPE’s modern burner generation represent proven solutions for

sustainable boiler modernization. However, for successful low NOX firing rehabilitation, infil-

trated air needs to be reduced – it should not exceed 15 % (lignite) or 5 % (bituminous coal)

at furnace exit. Therefore, seal tightness issues also need to be considered – something

which is also beneficial for economic plant operation.

not only mills and burners

In connection with a rehabilitation of the firing

equipment, HPE also analyses the impact of

changes in boiler heat transfer due to com-

bustion air reduction – as it is the case with

most low NOX rehabilitations (see also typical

sketch for a revamp with RS® Burners).

Given obvious variations, we would propose

measures to secure the original steam

parameters either at the turbine entry or

at the district heating extraction system.

Existing: Jet Burner λ = 1.29 no OFA

New: RS® Burner λ = 1.18 with OFA

Boile

r Hei

ght/

Flue

Gas

Pat

h

Flue Gas Temperature

BurnerZone

Furnace Exit

Typical

➔ Over Fire Air

Low NOx Rehabilitation: Temperature Profiles


Maximum Quality

in contrast to most other solution provider, Hitachi Power Europe can utilize its own

manufacturing.

This includes pressure parts for utility steam generators and headers (at “Meeraner Dampf-

kesselbau GmbH”), coal mills and burners (“Babcock Fertigungszentrum GmbH”), material

handling systems and steel structures (“Donges SteelTec GmbH”). As a result, HPE is not

primarily tied to sub-contractors and creates a true “Alliance for Quality”.

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 HPE’s subsidiaries have established special priori-

ties in controlling production quality. Thanks to constant refinements in high-tech materials

involving, for instance, special alloys for pressure parts, components can be used even more

economically and in a more environmentally compatible manner. Based on this experience

and depending on the project prerequisites, co-operation with local partners is also an option.

Our Own Manufacturing Facilities

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Success Products

The Grinding System – Key Component with Huge Refurbishment Potential

Optimized grinding in terms of throughput and grinding fineness and by in parallel

minimization of wear is the goal of mill rehabilitations. Even without any firing upgrades,

HPE has attained remarkable plant improvements which, in the main, have impacted

positively on boiler operation efficiencies.

As a specialist for mills with its own technology, HPE possesses enormous competence in all

kinds of mills and coals for new installations and upgrades – the latter also for “Non OEM”

mills. HPE’s comprehensive knowledge on grinding and fluid dynamics within the mills /

classifiers and their optimization potential allows the company to improve matters through

simple design measures backed up by CFD simulation.

DGS® Mills, NV Mills, N Mills for Lignite

The main challenge behind a lignite mill upgrade is to optimize the contradictory targets of

fuel throughput and grinding fineness in such a way that the increase of fuel throughput –

mostly in connection with improved grinding fineness – can be obtained by a minimum of

wear with consideration given to the permitted conditions (temperature, oxygen content).

Performance can often be improved remarkably without the need to invest in any increase of

fan wheel speed or fan wheel diameter – something usually requiring either an upgrade or

replacement of, for instance, the wheel itself, shafts, bearings, drive and coupling.

Efficient constructive measures either in the preheater section (for DGS® mills), classifier

(NV, N mills) or in the mill housing are HPE’s specialty for tapping the full potential of the

mill – again supported by cfd simulation.

Exemplary for HPE’s competence is the upgrade in Weisweiler PP at fan mill

N80.75. Instead of the requested contractual throughput increase of almost 10 %,

the reasonable measures which HPE took resulted in a 40 % increase


MPS® Mills for Bituminous Coal

The performance of vertical spindle mills depends on the geometric dimensions, revolution

speed of the grinding table and the grinding force itself.

As a prerequisite for these mill upgrades it needs to be ensured that sufficient delivery air is

available and that the mill primary air pressure as well as mill drive power have the required

margins. This necessitates also investigating the mill motor, PA fans and pf-piping in detail.

Application of the above measures for variable adjustment of dust fineness during operation

also secures higher flexibility during load changes and a temporary increase of pulverized fuel

outlet capacity.

MPS® MillMeasures for increasing grinding capacity:

■ Conversion of existing gearbox or replacement by new gearbox to increase the mill table speed

■ Implementation of an adjustable hydraulic grinding force system

■ Increase of maximal grinding forces by reinforcement of bearings, drives, tension frame, tension rod, hydraulic system, etc.

■ Optimization and new design of grinding rollers and grinding segments

with the latter two being complex solutions securing capacity increases of up to 60 %

Measures for improved grinding fineness (steeper distribution curve):

■ Replacement with new dynamic classifiers, often in existing classifier house

■ Classifier drive equipped with frequency inverters

Both comparatively simple conversions which by maintaining pulverized fuel fineness increase mill throughput by up to 10 %

U.S. Standard Sieve

Particle Size in µm

V6

Pass

ing

(%)

Resi

due

R (%

)

400

63 90 20050 70 150 300 70050030

270 200 100 70 50 30

50

40

30

20

10

1.0

0.1

0.01

60

50.00

60.00

70.00

80.00

90.00

99.00

99.90

99.99

40.00140

V3 V1 V5

0 rpm

110

rpm

100

rpm

85 rp

m

SLS Classifier – latest classifier design

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Success Products

State-of-the-art Combustion with Proven Burners from HPE

HPE’s ongoing burner fleet covers the whole fuel range for thermal applications

■■ For all fossil fuels – from anthracite via bituminous and sub-bituminous coal up to lignite,

including pre-dried lignite as well as different kinds of oil and gas qualities

■■ For many biomass applications and their dried or torrefied variants

All burners are based on the same design philosophy, which derives from HPE experts’

knowledge and detailed understanding about the ignition and combustion process.

Full combustion control

HPE’s burners are characterized by excellent ignition thus ensuring controlled combustion

over a wide range together with high flame stability and low emission values. Due to their

features the burners can cope admirably with high fuel flexibility. Firing systems designed for

problematical coals can be significantly simplified. HPE’s burners are designed for stoichio-

metric conditions. This impacts positively on the fouling and slagging behavior – even with the

properties of problematical fuels – and optimally protects the furnace walls against corrosive

flue gas products.

The principle of staged burner design is focused on fuel treatment to prepare the particles for

pyrolysis and ignition under the required conditions. The characteristic features are expressed

by the definition of initiation and course of ignition – with the latter meeting the equation:

IGNITION = PYROLYSIS + OXIDATION

HPE Burner Fleet

lignite / brown Coal

Sub bituminous

bituminous anthracite biomass (co-firing)

biomass (stand-alone)

Oil / Gas

bFG Turn down ratio (Control range)

burner Size MWth

pf dried pf dried pf dried pf dried pf dried pf dried

DS® X X X X X 1 : 3.5 20 – 100

RS® X X X 1 : 2 30 – 80

DST X X X X X X 1 : 17 20 – 60

ADS X 1 : 4 10 – 60

SG X 1 : 2 20 – 60


All HPE burners are of concentric design with swirl flow in all sections and devices such

as fuel nozzle and deflection cones. The CFD supported design ensures best combustion

performance in line with fuel and furnace requirements.

All burners apply staged combustion as an intermediate sub-stoichiometric primary flame

securing low NOX values, combined with sufficient secondary / tertiary air supply even for

over-stoichiometric combustion.

Following operational highlights characterize HPE-patented burners

■■ Excellent flame stability even under high fuel flexibility

■■ Stable flame attachment to the fuel nozzle

■■ Extensive burner control range with good part load performance

■■ Very low NOX emissions due to focus on pyrolysis and ignition processes

■■ Benefits of stoichiometric / overstoichiometric operation

(less fouling / slagging, corrosion protection)

■■ Easy replacement or adaptation to existing burner

■■ Minimum wear with a minimum 5 years / 24,000 hrs. lifetime guaranteed

Secondary Air Swirler – CFD Optimized Design

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Success Products

DS® Burner for Bituminous Coal

DS® burners were introduced early in the 1990s and continuously developed over the

years. Since 1992 more than 1,500 burners of this type have been successfully placed into

operation and applied both in new installations and rehabilitations. This staged burner type

can be used in direct firing systems for nearly all kinds of pulverized solid fuel qualities.

The burner has a concentric design with swirled flow streams in all burner sections. The DS®

Burner is the first of its kind enabling the above controlled ignition and staged combustion

process. It represents the basis model for the development of the other burner types. Due to

its excellent flame stability, the DS® Burner comes up with a control range of 1: 3.8 whereas

normal coal burners are limited to 1: 2. The burner is suitable for individual combustion air

supply as well as windbox arrangements.

Igniter

Pulverized Fuel

Adjustable Swirlers

Core Air Secondary Air

Tertiary Air

Fuel Nozzle

DS® Burner

DS®W Burner Design for a Windbox Arrangement

DS® Burners are also suitable for biomass co-combustion, as shown with

DS® Burner flame (35 MW), co-combustion coal (60 %) + sawdust (40 %)


RS® Burner for Lignite

logical progression of a successful burner generation comes in the form of RS® burner

development for lignite combustion. in contrast to conventional jet burners, the innovative

RS® burner concept is focused on stable fuel ignition at the burner tip.

This principle coming from DS® Burner technology has proved its success in many applications

where existing jet burners have been completely refurbished by burners of this type. Close on

150 burners have been installed at a total of 10 boilers.

The new boiler at Boxberg Unit R (670 MW – commissioned by end of 2011) is the first of

its kind which is equipped with RS® Burners in an “all-wall-firing concept”. This convincing

concept – from the arrangement point of view as well – will be applied in all new lignite boilers

designed by HPE.

Total control over the lignite combustion process

Under the requirement of keeping to the requested NOX emission values, the RS® Burners permit

over-stoichiometric operations – in contrast to jet burners. This has the following advantages:

■■ Reduction of multiple overfire air elevations

■■ Reduction of a slagging tendency due to convenient combustion air supply

■■ Protection against furnace wall corrosion, especially in cases of high fuel sulfur content

HPE’s main interest within firing rehabilitation lies in replacing jet burners by RS® Burners with

their favorable operational behavior. It has been proved that this leads to a sustainable solution

of all firing problems.

N. B. Where no RS® Burner refurbishment is intended (e. g. due to budget reasons), HPE

can, of course, also upgrade existing jet burners with RS® Burner functionality being used

as much as possible. Precondition: HPE’s internal pre-investigation demonstrates that this

is an appropriate measure for meeting the guaranteed performance values.

Secondary Air

Fuel Nozzle

RS® Burner

For further technical details also consult the HPE flyer “RS® Burner”

In contrast to the squared jet burners the circular-shaped RS® Burners are equipped with the described features

16

Success Products

DST Burner for all Pre-dried Pulverized Fuels

The DST burner has recently been developed on the basis of the DS® burner concept for use

in indirect firing systems. This burner type is the right one for all kinds of pre-dried pulver-

ized fuels. Pulverized fuel loading can be amount from 0.5 kg up to 15 kg fuel / kg medium.

These burners have a considerable turndown rate of up to 1:17 and are thus ideal in support-

ing flexibility issues. DST Burners can be used for atmospheric operation or in pressurized

systems with air and / or oxyfuel atmosphere. Air, inert gas and flue gas with or without oxygen

enrichment can be used as the delivery medium. An extensive testing program has come up

with a convincing performance in a burner test facility as well as during the test period at the

Oxyfuel pilot plant at the Schwarze Pumpe site.

Biomass, e. g. in the form of pellets or woodchips, can be used

in HPE’s DST Burners

Igniter

Core AirSecondary Air

Tertiary Air

Pulverized Fuel

Swirlers Fuel Nozzle

DST Burner


ADS Burner – Oil / Gas

aDS burners are HPE’s low-nOX answer to the combustion questions surrounding liquid

and gaseous fuels and which are used with industrial boilers and utility steam generators.

They can be designed as single fuel type burners and for multi-fuel operation. ADS Burners

are available for the front wall, opposed installation or as bottom burners; they are also used

as startup burners in utility units.

SG Burner – BFG

SG Burners are used for low calorific fuel like Blast Furnace Gas (BFG / BOFG), mulitfuel

applications like COG, NG and oil. For best combustion performance, fuel and air flows are

also influenced by swirlers and other devices.

Oil Gun

Secondary Air

Multi-Spot Gas Nozzles

Adjustable Swirler

SwirlerOil Nozzle

ADS Burner

Contours of temperature: Eshkol Power Station ADS Burner for Gas Firing

Secondary Air BFG COG

NG Primary Air

IgniterOil Gun

SG Burner – BFG

18

Solutions to Increasing Plant Flexibility

Priority in Future Plant Optimization is Shifting

in the past, the main issues have been efficiency and availability for producing power

under best economic conditions from a maximum of plant utilization. in future, besides the

network stability requirement there is also the challenge – even from reduced efficiency

and on fulfilling the progressively tougher emission values – of generating and selling

power as often as possible on the power market during the limited high price conditions

so as to secure plant commercial feasibility.

Related challenges of future flexible coal unit operations are

■■ Good part load properties combined with a steeper load ramp

■■ Frequent startups

■■ Extension of coal operation down to lowest minimum load (1-mill operation)

■■ Reduction / avoidance of valuable oil / gas during start up, low load

■■ Everything done with consideration given to the existing emission limits (mainly NOX)

From the firing point of view, HPE has suitable concepts supported by modern low emission

burner technology as described above. Moreover, HPE also possesses concepts for indirect

firing. During energetic optimized operation and / or during low power prices, fuels are ground

and stored independently from the boiler operation and on request are immediately available.

The related integration into existing plants – also in connection with optional utilization of

dried biomass – was investigated by HPE in several studies and is ready for implementation.

Solutions to reduce oil and gas under startup optimization conditions also exist. System

warming by hot gas heating of only one MPS® mill allows early coal fire for that one mill.

This, in turn, takes over overall system heating for the full coal operation, thus considerably

reducing expensive start-up fuels. Startup technologies without oil / gas are being developed.

Fuel flexibility solution (biomass conversion)

In Europe the trend is towards CO2-neutral combustion of biomass such as wood chips,

wood pellets, saw powder and plants / fruits as residues (corn, husk of citrus fruits, olive pits

etc.) and torrefied variants. To this end, HPE recommends boiler modifications for co-

combustion of biomass in utility size plants to avoid high investment cost in new plant. HPE

has suitable burners for solid biofuels as well as references and concepts for handling,

storage and fuel preparation – and this in partly modified bituminous coal and lignite mills.

Precondition for flexibility – Upfront comprehensive investigation

All the systems involved and their elements such as steam, combustion, flue gas cleaning etc.

need to be investigated in detail as to their eligibility for the intended operational mode.

The main criteria such as full load, NOX emissions, boiler performance, plant integration

and adaptation requirements for fuel logistics – including explosion protection for biomass

application – also need to be considered. HPE has the required expertise in overall solutions

for all kinds of flexibility upgrades.


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 operation-

ally 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 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 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 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 CO2 emissions cut. The latter can also be achieved by using an

indirect firing system combined with DST Burners burning (e. g.) woody biomass .

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.

G

DST Burner

100% Biomass Capable

Cyclone

Coal Dust Bunker

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5 GT repowering

20

Rehabilitations – References

Mill Upgrading – Extract

Power Plant Country / MW / Fuel

Mill TypeStart-Up / Retrofit

Retrofit Measure aim of Retrofit

Frimmersdorf Q Germany / 300 MW / Lig

N 200 1970 / 1998 Retrofit of classifierIncrease of grinding fineness Reduction of temperature

Nanticoke Canada / 512 MW / Bit

E * 1978 / 1998 Retrofit of classifierIncrease of grinding fineness Reduction of unburnt low NOX firing

Reuter Germany / 320 MW / Bit

MPS 170 1987 / 1998Replacement of classifier, sealing system, modification of pf ducts

Increase of grinding fineness Reduction of unburnt low NOX firing

Elverlingsen Germany / 330 MW / Bit

MPS 170 1982 / 1998Replacement of classifier Retrofit of mill

Increase of grinding fineness Reduction of unburnt

Veltheim Germany / 330 MW / Bit

MPS 150 1970 / 1999Replacement of classifier Retrofit of mill

Coal change, capacity increase Increase of grinding fineness Reduction of unburnt

Oroszlany Hungary / 60 MW / Lig

NV 32 1962 / 2000 New design of classifierMill capacity increase Increase of grinding fineness Lifetime extension of wear parts

Neurath C Germany / 300 MW / Lig

DGS 90 1973 / 2000 New rotor, RPM increase Mill capacity increase

Wilhelmshaven Germany / 720 MW / Bit

MPS 235 1976 / 2002Adjust. grinding force, modification of classifier outlet

Mill capacity increase

Niederaußem B Germany / 150 MW / Lig

N * 1962 / 2002 Retrofit of classifier Mill capacity increase

Amer 9 Netherlands / 600 MW / Bit

MPS 235 1992 / 2003 Retrofit of mill parts Conversion to biomass fuel

Heyden Germany / 900 MW / Bit

MPS 255 1987 / 2005Adjust. grinding force, RPM increase, modification of pf ducts

Mill capacity increase

Kiel Germany / 320 MW / Bit

MPS 180 1970 / 2005 Retrofit of dynamic classifier Mill capacity increase

Mehrum Germany / 650 MW / Bit

MPS 1901979 / 2008 / 11

Replacement of classifier (static to dynamic)

Mill capacity incrase Increase of grinding fineness

Weisweiler G,H Germany / 600 MW / Lig

DGS 1301974 / 75 / 2008

Retrofit of mill parts Mill capacity increase

Weisweiler D Germany / 300 MW / Lig

N 80.75 * 1965 / 2008 Retrofit of mill parts Mill capacity increase

Nikola Tesla A Serbia / 308.5 MW / Lig

DGS 1001976 / 2010 / 11 / 12

Redesign of mill parts new rotor, RPM increase

Mill capacity increase Increase of grinding fineness “Low NOX ready”

Kostolac B Serbia / 348.5 MW / Lig

N 275.45 *1991 / 2010 / 12

New design of classifier Retrofit of mill

Mill capacity increase Increase of grinding fineness

Atikokan Canada / 226 MW / Bit

MPS 190 (75 inch)

1985 / 2012 Redesign – engineering of mill parts Conversion to biomass fuel

Altbach Germany / 347.5 MW / Bit

MPS 150 1997 / 2012 RPM increase, new nozzle ringMill capacity increase Reduction of pressure loss

* mills from other suppliers


Firing Rehabilitations with HPE Burners – Extract

Power Plant Country / MW

burner Type

Fuel Kind of firingno. of burners

burner load MWth

year of Commissioning

Sostanj III Slovenia / 275 MW

RS® Lignite Tangential 4 31 1994

Niederaußem B Germany / 150 MW


Niederaußem A Germany / 150 MW


EDF Vitry 3 France / 250 MW

DS® Bituminous Front 24 35 1998

EDF Vitry 4 France / 250 MW


Ontario Power, Nanticoke Unit 2 + 4 Canada / 500 MW

DS® Bituminous Opposite 80 35 1999

Cascades Arnsberg, Unit 1 Germany / 60 t / h

DS® Semi-anthracite Opposite 8 6 1999

Heyden P.S. Germany / 900 MW


Ljubljana Boiler 3 Slovenia / 50 MW-CHP


Neurath A Germany / 320 MW


Neurath B Germany / 320 MW


Cascades Arnsberg, Unit 2 Germany / 60 t / h

DS® Semi-anthracite Opposite 8 6 2000

Ontario Power, Nanticoke Unit 1 Canada / 500 MW


GKW Kiel Germany / 350 MW


Niederaußem, Unit C1 / C2 Germany / 300 MW

RS® Lignite Roof 2 x 6 76 2001

GKW Hannover, Boiler 1+ 2 Germany / 145 MW


Stockstadt, Boiler 9 Germany / 165 t / h


Wilhelmshaven Germany / 800 MW


Weiher P.S. Germany / 650 MW


Eshkol C, Boiler 6 + 7 Israel / 230 MW

ADSHeavy fuel oil, natural gas

Opposite 2 x 16 40 2002

Sostanj IV, Unit 5 Slovenia / 345 MW


Eshkol D, Boiler 8 + 9 Israel / 230 MW

ADSHeavy fuel oil, natural gas

Opposite 2 x 16 40 2003

Ontario Power, Nanticoke Unit 5 Canada / 500 MW

DS® Sub-bituminous Opposite 40 35 2006

Narcea Spain / 350 MW

DS® Anthracite Roof 24 36 2006

La Robla Spain / 350 MW

DS® Semi-anthracite Roof 24 36 2007

TENT A5 Serbia / 308.5 MW


La Cygne – Kansas USA / 715 MW

DS® Sub-bituminous Opposite 56 35 2012

22

Inspire the Next

Hitachi Power Europe GmbH

Schifferstraße 80

47059 Duisburg, Germany

Phone +49.203.8038-0

Fax +49.203.8038-1809

[email protected]

www.hitachi-power.com

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