State of the Art Power Technologies

Modernisation and new Power Plants

“Efficient and Clean Coal Technologies;
State of the Art Power Plants and future research efforts in Germany and the EU”

Franz Bauer Matthias Zelinger

VGB PowerTech VDMA
 State of the Art Power Technologies

State of the Art Technology

are dealing with the following topics

™ Concept and Construction of new Plants

™ Modernisation of existing Power Plants
 State of the Art Power Technologies

the Development of Power Plant Technology

is driven by
Electricity Market & legal Requirements
open Market Æ Demand and Supply
Requirements ÆLarge Combustion Plant Directive
Required New Capacity from 2010 Onwards

Installed Capacity
EU-15 (GW)
900
Power Plants Younger
800 than 40 Years
700
600
Miscellaneous Supply Gap
500
Gas
400
300 Coal
200 Nuclear
100
Hydro
0
2000 2005 2010 2015 2020 2025 2030
 VGB
PowerTech

Age of Coal- Fired Power Plants in Europe

24 200
22 180
Percentage of Installed Ccoal-

20
Fired Capacity in Europe

160
18

Number of Plants
140
16
14 120
12 100
10 80
8
60
6
40
4
2 20
0 0
0-5 5-10 10-15 15-20 20-25 25-30 30-35 35-40 >40
37 % 63 % Years
VGB
PowerTech
Oil and Gas Prices – History & Perspectives
90
€'2005/bbl
80

70

60

State of the Art Power Technologies

Oil
50

40

30
Gas
20

10
Coal
0
1980 1985 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 2045 2050

a wrap up based on Eurelectric/NTUA and VGB paper

Modernisation of existing Power Plants
Modernisation – an Opportunity for efficiency Increase

Steps of Modernisation
™ Fulfilling the Legal Requirements
™ Flue Gas Cleaning
Up-grading Electrostatic Precipitator
Installation of De-sulphurisation System
™ Primary Combustion Control
™ Improvement of Life Time and Reliability
™ Installation of Instrumentation & Control System
™ Exchange of end of life Components
™ Efficiency Increase
™ Replacement of low pressure Turbine Blades
Modernisation – an Opportunity for efficiency Increase
KW Jänschwalde (Noell-KRC) KW Boxberg (Steinmüller)

Comparison of two De-sulphurisation System

Modernisation – an Opportunity for efficiency Increase

Key Elements of Retro-fit Cooling Tower

™ Orifices for the Installation of the Flue Gas Duct
™ Installation of the Flue Gas Support Structure
™ Dismantling and Installation of new System
™ high-efficient Cooling Devices
™Spray System
™ Water Collection System
™ Up-grading of Water Supply System
™ Sealing of the Walls
™ Replacing of Ducts and Pumps System
Modernisation – an Opportunity for efficiency Increase
KW Jänschwalde (Noell-KRC) KW Boxberg (Steinmüller)

Concept of De-NOx System for 500 MWel

Modernisation – an Opportunity for efficiency Increase

KW Jänschwalde (Noell-KRC) KW Boxberg (Steinmüller)

De-NOx Fuel Compression Fuel Compression

Main & Secondary Burner Main Burner
burn-out 1 jet burn-out 3 jets
2 lances
Control Air Use < 75 % by
higher tightness and burn-out grate
Pressure Part partially replacement of pipe-work/systems
temperature/pressure control (spray cooler)

Concept of Boiler Modernisation Measures

Modernisation – an Opportunity for efficiency Increase

Tendency of Plant Reliability after Modernisation of 500 MWel Units

Modernisation – an Opportunity for efficiency Increase

Emissions of KW Jänschwalde Unit B 500 MWel

lowest/highest daily average Values 08/1996
Modernisation – an Opportunity for efficiency Increase

Emissions of KW Jänschwalde Unit B 500 MWel

Comparison daily average Values with previous Values 1991
 Modernisation – an Opportunity for efficiency Increase

System previous boiler turbine cooling De-SOx new

Heat Consumption 8705/8930 - -360/460 -44 - 8370/8490

Turbine kJ/kWh

Boiler Efficiency % 84,0/85,0 +4,2/5,8 - - - 89,1/90,2

Auxiliary Consumption % 5,2 - - - +2 7,2

Unit Efficiency, net % 31,0/32,0 +1,5/2,2 +1,5/1,9 +0,2 -0,7 35,5/36,1

Efficiency Increase of the B 500 MWel Units

nominal load
Modernisation – an Opportunity for efficiency Increase
VEAG /.Vattenfall
Units

Units

Units

Mean Values of forced Outage Rate of Vattenfall Lignite Power Plants

Modernisation – an Opportunity for efficiency Increase

specific consumption, Ref 1989

Units
VEAG /.Vattenfall
Units Units

Mean Values of specific Consumption of Lignite (brut) of

Vattenfall Lignite Power Plants
Modernisation – an Opportunity for efficiency Increase
Emission Cost

Cost of modernisation in mio DM/a

Emission factor in t/kt Lignite

Emission Reduction versus Cost of Modernisation 500 MWel Units

State of the Art Power Plant Technology
Efficiency Potential of Steam Cycle Power Plants
100

90 Natural Gas Thermodynamic

Efficiency
Coal Limit
80 Nuclear Power (Carnot)
Reduction of efficiency
through additional Components,
70 Internal Consumption etc.

Combined es
60 Cycles: t e am Turbin
Efficiency [%]

S
Gas +
Pressurized erized
50 Fluidised-Bed s su riz ed pulv
pre l comb.
Combustion coa

IGCC
40 Light Water
Reactor
Gas Turbine
30 Steam Turbine
incl. Flue Gas
Desuphurization,
20 Denitrification

10

200 400 600 800 1000 1200 1400

Upper Process Temperature / Turbine Inlet Temperature (ISO) [°C]

ÆAttainable Efficiencies of Steam and Gas Cycles

Technology Perspectives in terms of Efficiency
Coal Oil / Gas

Gas+Steam
Steam Steam Comb.
IGCC
Cycle Cycle Cycle

Techn. Status 1985 38% 40% 42% 48%

Techn. Status 2000 47% 49% 49% 58%

Estimation 2010 50% 55% 52% 60%

Æ Steps in Efficiency: Status and Outlook

 Efficiency Æ Hard-Coal fired Power Plant
51

50
0,6
49 0,6 waste-heat
350 bar
0,4 pressure recovery
700/
Net-Efficiency [%]

48 720°C 0,8 efficiency loss, at the

of steam internal steam
double turbine
47 300 bar reheating consumpt. generator
285 bar 625/ 1,6
46 600/ 640°C
270 bar
620°C
585/ 0,7
45 600°C
250 bar 0,6
44 540/
560°C
1,3

43 167 bar
538/ 1,5
538°C
42

41
X 20 X 20 P 91 NF 616 NF 12 Inconel
advanced materials advanced processes and components

Source: Siemens/KWU 1999 - Aspects of Clean Coal Technologies

Efficiency Improvement = Learning Curve
48

46 Waste
Heat 45,2%
Condenser
1,3%
44 pressure
Auxiliary
consumption 1,4%
Net-Efficiency [%]

42 Process
1,5%

Niederaußem K (BoA)
optimization

40 Steam- 1,6%

1000 MW
parameters
Steam- 1,6%
38 Turbine

2,3%
36 35,5%
Neurath E
600 MW

34

32
1976 Year of Commissioning 2002
Source: Benesch
- Example: Lignite-Fired Plants in Germany
(resp. RWE)
 State of the Art of Power Technologies
for Lignite and Hard Coal
BoA 1, 1012 MW, Kraftwerk Niederaußem

Status Operation since 2003

Steam Parameter 275 bar / 580°C / 600°C
Netto-Efficiency > 43 %
BoA 2/3, 1100MW, Kraftwerk Neurath

Status Planung, 2010 in Operation

Steam Parameter 272 bar / 600°C / 605°C
Netto-Efficiency > 43 %
Referece Plant NRW

Status Studie
Steam Parameter 292 bar / 600°C / 620°C
Netto-Efficiency 45,9 %

„ High Potential for Security of Supply, Affordable Prices and Climate Protection
„ Lessons learnt Æ Experience, Skills and a clear Will for Change

Source: RWE Power

Concept and Construction of new Plants
Modern Steam Power Plants
NRW Reference Plant
600 °C Technology

… basis of the new planned projects

Overall Data Set NRW Reference Plant
Boiler Concept
Thermodynamic Cycle NRW Reference Plant
Experiences with State of the Art
BoA 1 – Outages 2003/2004 (2)
Rupture Lubeco-Ash Catcher: too high Filling due to Loss of Ash Transportation System,
Density of the Ash by 50 % higher as Design.
- Loss of Availability: 13 % in the year of Damage
- Loss of Power: 0,9 TWh

Plastic deformation of the

Lubeco-Ash Catcher

Lubeco RG-Kühler
LuVo

E-Filter Lubeco

Wasserluft-
vorwärmer Lubeco-
entaschung

Asche-
trichter

by Implementation of new Components based on new Concepts & Materials

Æ only Skills and Experience count for.
Source: RWE Power
Experiences with State of the Art
BoA 1 – Outages 2003/2004 (2)
De-plaquing of inner Magnetite Layers in SH5 / RH3 (April 2004)
=> Deposits → Blockage → over-heating → Pipe Rupture
- Availability Loss: 24 % in the year of Damage
- Loss of Power: 1,7 TWh
Replacing RH 3 by DMV 310N (Juni 2004)
- Availability Loss: 26% in the year of Damage
- Loss of Power: 1,8 TWh

Nadelförmige
Abplatzungen

Röntgenaufnahme
eines Bogens ZÜ 3 mit Rohrreißer
Magnetitablagerungen am ÜH 5

Material X3CrNiMoN17-13 used for the first time at high Temperatures of 580/600°C .
=> Sufficient Tests under operational Conditions are required!
=> Investigation on Material-Testrings are important and necessary!
=> Appropriate Design Solutions have to be considered.

Source: RWE Power

 Experience with State of the Art Technique
at the example of the material development
100.000 h Life Time Limitations for E911 and P92
Decrease of tolerable Stresses respective Temperatur
200

175 P92
MPa150
Previous Values P92 ASME 2004
E911 P92 ECCC 1999
New Values P92 ECCC 2005
125
E911 VdTÜV 1998/2001
Orientation
100 E911 ECCC 2005
Punkt (XY) 6
75
°C
50
550 575 600 625 650

„ Recent Evaluation of Experiences

Temperatur °Chas caused a Decrease of reduced Life Time

„ Material Development needs Time and Time and Money, but also high Skills

Source: RWE Power

Actual projects for Development and Test of new Materials
KOMET 650 AD 700 Comtes 700 (ab Comtes 700 (ab Esbjerg, bis 720°C Weisweiler G, Weisweiler G,
Martensitische, Schwerpunkt: hoch Mitte 2005, Mitte 2005, (Neubestückung Ü- 720°C 650°C
austenitische und nickelhaltige und Scholven) Scholven) Testschleife (Neubestückung Ü- (Neubestückung Ü-
Nickelbasiswerksto Nickelbasiswerksto Schwerpunkt: Schwerpunkt: geplant ab Mitte Testschleife geplant Testschleife geplant
ffe für Überhitzer ffe Komponententests Komponententests 2004) ab Mitte 2004) ab Mitte 2004)
und Rohrleitungen, Beispiel: Hier: Hier:
Tmax. 650 Testschleife Verdampferwerksto Überhitzerwerkstof
Weisweiler, Tmax. ffe bis max.610°C fe bis max.705°C
E911 und P92 AC 66 (Fe-Ni-Cr-
700°C 13CrMo4-5 P92 (9%Cr- TP347HFG TP347HFG TP347HFG
(9%-Cr Leg.) (Ferrit, Martensit, (Feinkornaustenit) shotblasted, shotblasted,
Martensite) Eintrittsammler, Eintrittsammler, Hersteller DMV Hersteller DMV
390°C) 580°C) (Feinkornaustenit) (Feinkornaustenit)

Werkstoff- Alloy 617 (Ni- T 24 HR3C Sumitomo HR3C Sumitomo Super 304H Werkstoff-
Nr.1.4910 und Basis) (7CrMoVTiB10- (hochlegierter (hochlegierter shotblasted, Nr.1.4910
1.4941 10, Ferrit, 495°C) Austenit, 635°C) Austenit) Hersteller shotblasted
(hochwarmfeste Sumitomo (Standardaustenit)
Standardaustenite (patentierter
)
TP347HFG und Alloy 740 (Ni- HCM 12 (12%Cr- TP310NbN DMV Sanicro 25 Feinkornaustenit)
HR3C, Hersteller Super 304H
Esshete1250 Basis) Martensit, 555°C) (wie HR3C) (hochlegierter Sumitomo shotblasted,
(Feinkornaustenit Austenit) (hochlegierter Hersteller DMV
e) Austenit)
Super 304H, Alloy 263 (Ni- Alloy 617 (Ni- Sanicro 25 (Alloy Alloy 617 (Ni- TP310NbH, Super 304H
Hersteller Basis) Basis, 610°C) 174, hochlegierter Basis) Hersteller DMV shotblasted,
Sumitomo Austenit, 635°C) (wie HR3C) Hersteller
(patentierter Sumitomo
Feinkornaustenit) (patentierter
NF709 P92 (9%Cr- Alloy 617 (Ni- Alloy 740 (Ni- HR6W (Fe-Ni-Cr- Feinkornaustenit)
HR3C, Hersteller
(hochlegierter Martensit, Basis, 705°C) Basis) Leg.) Sumitomo
Austenit) Austrittsammler, (hochlegierter
610°C) Austenit)
AC 66 (Fe-Ni-Cr- Niedriglegierte warmfeste Stähle Alloy 740 (Ni- Alloy 617 (Ni- Sanicro 25 TP310NbH,
Leg.) Basis, 705°C) Basis, (hochlegierter Hersteller DMV
Martensitische 9-12% Cr-Stähle
Austrittsammler) Austenit) (wie HR3C)
Alloy 617 (Ni- Hochwarmfeste Standardaustenite 16- Alloy 617 (Ni- Alloy 617 (Ni-Basis) HR6W (Fe-Ni-Cr-
Basis) 18% Cr Basis, Leg.)
Feinkornaustenite ~18% Cr
Austrittsammler,
Hochleg. Austenit ≥22% Cr und Fe-Ni- 705°C)
Cr-Legierung Alloy 740 (Ni-Basis)
Ni-Basis Legierungen
700 °C Technology
…targeting the 50% threshold by achieving 700 °C steam parameter

„ COMTES 700 + Turbine Control Valve

Scholven, Block Power Plant.
EU-funded Project and Industry.

„ Testrigs in Esbjerg u. Weisweiler,

KOMET650 in Westfalen
own financial contribution

ÆTechnology Path towards

Ænear Zero Emission Power Plants based on fossil Fuels
a permanent challenge of all participants in close co-operation
Source: RWE Power
Pathway to USC 700°C Power Plant

USC 700°C
Laboratory (material development, creep data)
Power
7 00) Plant
M TES 0)
, CO 7 0

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R igs PP
Te st W

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t s ( N R
plan n
(
wer

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Tes ai

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sup
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B

Sit
European and German projects
1998 2007 2014
 Challenges of 700°C Life Steam Temperature

Tubes and Pipes big Valves

Designed by
Siemens

Superheater
and Reheater

Designed by
Siemens

Efficiency 600°C Technology:

Designed by Hitachi Power 45-46%
Europe Efficiency 700°C Technology:
50%
COMTES700 – Implementation into Boiler

Host Plant - Scholven F, E.ON

z Net output
- 676 MW

z Live-steam
- 220 bar (design pressure)
- 540 °C Superheater
- 625 kg/s (2,250 t/h) Evaporator

z Reheater-steam
- 44 bar
- 540 °C
- 568 kg/s (2,044 t/h)

z Fuel
- Hard coal
COMTES700 – Material Concept Outlet
Alloy 617 P 92
Evaporator

HCM 12

7 CrMoVTiB 10 10/T 24

2,046 mm
43 x 48 =
44 parallel tubes
Inlet
8,800 mm

Source: Alstom 13 CrMo44

 COMTES700 – Material Concept

Superheater

Alloy 617 Alloy 740 HR3C / TP 310N Alloy 174

Outlet

1,050 mm
15 x 70 =
Inlet 16 parallel tubes 17,812 mm

P 92

Source: Alstom
700 °C Steam Pipe
Future Perspectives of Plant Technology
Carbon Capture & Storage
CO2-Capture & CO2-Storage
CO2 can either separated from the flue
gases or from the fuel before the
combustion process.
CO2 will be purified and for permanent
storage compressed in liquefied form in
poroseous rock formations.

CO2-Capture
• Post-Combustion in
conventional Power
Plants
• Pre-Combustion in
Power Plants with
integrated Gasification
• Oxyfuel-Combustion
CO2-Storage
• deep saline Aquifere
• Exhausted Oil- and
Gasfields
• not-minable Coal Seams
• Mineralisation

Intensive Research is necessary for both areas Capture & Storage.

Acceptance for CO2-free Power Plants can only be achieved by a clear
Validation and Confirmation of the Storage Cpabilities.
State of the Art Power Plant Technology
State of the Art Technology Path
stands for
• Focussing of Efforts & Resources
• Appropriate Sequence of any Step
• Robust Scenarios respecting technical AND
political Implication and Consequences
• Efficiency in Pursuing the defined Goals
…thinking in Visions
having Concepts in mind
leading to key components !
 Strategy for CO2 Reduction in Power generation

Horizon I Horizon II Horizon III

worldwide Application of
Efficiency-
State of the Art Technologies
Increase
CO2 Reduction
advanced Technologies, e.g. 700 °C

Vision: CO2 free fossil based Power Plant CO2 Capture

 Thank you for your Attention

AD700, COMTES700 and PP/700 are Projects with co-funding

of European Union, DG RTD & Regional Fund
 Questions?

Franz Bauer
+49 201 81 28-250
franz.bauer@vgb.org
www.vgb.org