Babcock Borsig Steinmüller GmbH Best practices in ... · Babcock Borsig Steinmüller GmbH DESIGN...

Best practices in rehabilitation of existing

power plants in Europe - Rehabilitation of

Belchatow Power Plant Dr.-Ing. Ralf Peter / Mechthild Angleys

Babcock Borsig Steinmüller GmbH

Johannesburg, November 05, 2012

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The Power Plant Bełchatów

Babcock Borsig Steinmüller

The power plant Bełchatów belongs to the largest

electricity producer of Poland, the PGE Górnictwo i

Energetyka Konwencjonalna S.A.

The installed power plant capacity of the PGE is

approximately 12,3 GW

The power plant Bełchatów originally had an

installed capacity of 12 x 360 MW

Starting from 2004 retrofit of old units by added

20 MW per unit

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Retrofit of coal fired power plants


The European power plant capacity needs to be replaced or modernized.

Due to the nuclear phase-out quick actions have to be taken

Renewables can not replace the nuclear capacity

Political acceptance for new Power Plants is critical

>>> one possible solution is the retrofit of old coal fired power plants.

The Bilfinger Berger Power Services Group set an example at Bełchatów Power Pant in

Poland. Babcock Borsig Steinmüller retrofitted the boilers 3 to 5 until 2011 and will modernize

the boilers 7 to 12 until 2016.

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Steps of the complex modernisation programme


Step 1

• Extending life time

• Increasing availability

Step 2

• Reducing emissions

• Complying with international environmental standards

Step 3

• Boosting capacity

• Increasing plant efficiency

Step 4

• Reduction of fuel consumption

• Extension of coal mine life time

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Belchatow PP, the biggest PP in Poland, originally equipped with

12 x 360 MW identical units.

Main equipments of units are:

• Boiler, type BB-1150,

• Turbine, type 18K360

• Generator, type GTHW360.

Turbine type 18K360 – delivered by Zamech , BBC licence

Commissioning: - unit #1 1982

- unit #12 1988 Blading system profiles 1000

LP exhaust D54 / ND37

Technical parameters:

Power output - 360 MW/370 MW

Live / reheat steam pressure - 17,6/4,0 MPa

Live / reheat steam temperature - 535 °C/ 535 °C

Live steam mass flow - 302.5 kg/s

Condenser pressure - 0,0068 MPa

Boiler, type BB-1150 delivered by RAFAKO

Original technical data :

Nominal capacity - 1150 t/h

Nominal thermal power - 750 Gcal/h

Nominal live steam pressure - 18,6 MPa

Nominal live steam temperature - 540 °C

Nominal reheat steam pressure - 4,5 MPa

Nominal reheat steam temperature - 540 °C

Nominal boiler efficiency - 88%

The main environmental installations:

- Electrostatic precipitator, type 2 HE-2x42-2x1600/3x5x11,6/300, delivered

by ELWO.

- FGD system, delivered by RAFAKO (units 3-12)

Generator type GTHW 360 delivered by Dolmel Wroclaw ,BBC license

Technical data:

Apparent power - 426 MVA

Active power - 370 MW

Voltage - 22 kV

Current - 11180 A

Power factor - 0,85

The Power Plant Bełchatów

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Optimising circulation process

Modernisation HP and MP turbine parts

Raising the SH and RH temperatures

Boosting the feed water temperature by installing HP- preheater 3

Boosting the steam generator efficiency


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Fundamental information of the boiler


Data Original

After modernization of boiler no. ….

3 4 5 7 bis 12

Live steam temperature 545

C 550

C 550

C 570

C 560

C

Live steam pressure 18,7 MPa 18,2 MPa 18,2 MPa 18,5 MPa 18,7 MPa

Live steam flow mass 1.090 t/h 1.100 t/h 1.100 t/h 1.120 t/h 1.125t/h

Reheatet temperature 545

C 570

C 570

C 570

C 570

C

Feed water temperature 255

C 255

C 255

C 275

C 255

C

Flue gas temperature after

Eco 305

C 305

C 305

C 305

C 305

C

NOx [mg/Nm³] 400 <200 <200 <200 <200

CO [mg/Nm³] 200 <200 200 <200 <200

▪ SULZER – once-through – single-pass boiler with circulation overlaid of the type BB-1150

▪ Ash extraction with 2 chain grates

▪ Start-up and stabilisation firing with MAZUT – burners

▪ 8 coal dust burner for lignite

▪ Coal quality: Heating value 6.500 – 8.700 kJ/kg; w = 47 – 56 %; a = 8,7 – 18,4 %

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Modernising the steam generator


Enlarging the SH1 superheater

Adjusting the RH1 reheater surface

Replacing the final superheater

Eco heating surface – replacing the

pipe elbows and adjusting the

heating surface

Replacement of connection pipes

and valves

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vor dem Umbau nach dem Umbau

Materialadaption of Pressure Parts

Existing Boiler New Boiler

surface

area

outer

diameter Material

surface

area

outer

diameter Material

m² mm m² mm

Eco 21813 38 16M 16350 38

16M

16 Mo 3 Partly replacement

P1B 20977 38 15HM 32000 38

16M 15 HM

13 Cr Mo 4-5

M1 6438 51 16M / 15HM /

10H2M 11050 51

16Mo3 10CrMo9-10

VM12

P4 3731 38 X20CrMoV12.1 3777 38 X8CrNi19-11

M2 2870 51 15HM / 10H2M / X20CrMoV12.1

3138 51 10CrMo9-10

P3 3120 44,5 15HM /

X20CrMoV12.1 2876

44,5 10CrMo9-10

P1A 184 44,5 15HM 369 44,5 10CrMo9-10

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Modernising the steam generator

Emission-reduction measures Babcock Borsig Steinmüller

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)

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Burners and over-fire air lances (OFA2)


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

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Timeschedule of contract execution


Main Scope data

▪ Dismantling mass in total: 3.494 to

▪ Number of welding joints: 88.000 pieces

▪ Assembly mass in total: 4.200 to

▪ New insulation: 46.200 m²

▪ Scaffolding: 55.000 m³

Timeschedule

▪ Engineering and delivery: 24 month

▪ Assembly period ( boiler outage ): 8 month

▪ Synchronisation 3 month

▪ Commissioning until PAC 2 month

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Dismantling and assembling of 750 to of heating

surfaces in 40 calendar days Babcock Borsig Steinmüller

Letting down of old modules

Completion of

one module

before lifting

Special goods

vehicle

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Results of the furnace optimisation Unit capacity and half-hour average CO and NOx values


NOx average value for day: 171 mg/Nm³

CO average value for day: 144 mg/Nm³

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Gas – Gas - Heater


Heat recovery system: using the flue gas heat at FGD

inlet for clean gas reheating downstream of FGD

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Gas-Gas Heater

Belchatow PP Babcock Borsig Steinmüller GmbH

DESIGN DATA:

FLUE GAS COOLER

Flue gas flow 1.700.000 Nm³/h f.

Temperature in/out 160 / 148

C

Water mass flow 153 kg/s


C

Heat duty 8,1 MW

CLEAN GAS REHEATER

Clean gas flow 1.820.000 Nm³/h

f.


C

Water mass flow 153 kg/s


C

Heat duty 8,1 MW

GENERAL

Reduction of CO2 11 t

Electrical Performance 2,5 MW el

Commissioning 20010 / 11

Gas Gas Heater around FGD

•Efficiency increase 0,8 %

•Reduction of coal consumption

21000 to per year

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Gas Gas Heater

Belchatow Power Plant Babcock Borsig Steinmüller GmbH

Timeschedule

•Realizationtime - 2 Month Basic-Engineering

- 13 month delivery and assembly

•Extreme narrow space condition

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Improvement of Boiler and Plant Efficiency


Data Original

After modernization of boiler no. ….

3 4 5 7 to 12

Live steam temperature 545

C 550

C 550

C 570

C 560

C

Live steam pressure 17,6 MPa 18,2 MPa 18,2 MPa 18,5 MPa 18,7 MPa

Live steam flow mass 1.090 t/h 1.100 t/h 1.100 t/h 1.120 t/h 1.125 t/h

Reheat temperature 545

C 570

C 570

C 570

C 570

C

Feed water temperature 255

C 255

C 255

C 275

C 255

C

Coal consumption 442 t/h 449 t/h 449 t/h 431 t/h 460 t/h

El. Output 360 MW 380 MW 380 MW 380 MW 390 MW

Efficiency 38,1 % 39,3 % 39,3 % 41,0 % 40,2 %

▪ SULZER – once-through – single-pass boiler with circulation overlaid of the type BB-1150

▪ Tangential firing system with 8 burner compartments

▪ Coal quality: Heating value 6.500 – 8.700 kJ/kg; w = 47 – 56 %; a = 8,7 – 18,4 %

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Results of the complex modernisation

Reduction of fuel consumption Babcock Borsig Steinmüller

Fuel consumption between now and 2045 has been cut by 70.9 million tons,

increasing the useful live time of the open-cast mines by approx. 1.5 years!

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Summary


▪ Emissions reduced to match international environmental

standards

▪ Lifetime extention by a further 200,000 h operating hours

▪ Unit efficiency increased by approx. 2%

▪ 71-million-ton reduction in lignite consumption increases

operating lifetimes of the open-cast mines and power station by

approx. 1.5 years

▪ Reduction of specific CO2 Emission from 1040 gr/kWh

to 961 gr/kWh

Thank you very much for your kind

attention! Mechthild Angleys, Babcock Borsig Steinmüller, Johannesburg


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