Beruflich Dokumente
Kultur Dokumente
Co generation in Pakistan
in Pakistan
DESCON Engineering Limited
Seminar at July 2010
1
What is meant by co‐generation
What is meant by co generation
Co‐generation is:
• A highly efficient means
of generating heat and electric
power
• At the same time
• From the same energy source.
Production of heat and electric separated
2
C t lP
Central Power generation
ti
Combined cycle plant Combined cycle plant
Simple cycle plant
with diesel engines with gas‐turbines
E E E
E E
Efficiency 32%
Effi i 32% Effi i
Efficiency 42‐45%
42 45% Effi i
Efficiency 50‐55%
50 55%
60% of heat
dumped in
dumped in
condenser
3
Co‐generation
Combined cycle plant
y p Combined cycle plant
y p
Simple cycle plant
Simple cycle plant
with diesel engines with gas‐turbines
E E E
Process Process Process
steam steam steam
E E
By i.e. extracting 50% process
steam 30% of heat will be
saved
4
Co‐generation without condensing
Efficiency of system can be increased in far extend by deletion of
condenser.
condenser
High heat losses in condenser are eliminated
E E E
Efficiency of power generation 85 till 93%
5
In cogeneration systems with combined cycles
g y y
Efficiency can be increased further by additional firing in HRSG
fuel fuel
E E
E Process E Process
steam steam
Cond. return Cond. return
Efficiency of power generated by additional firing is 100
till 120%
6
Effect of cogeneration on plant efficiency
More process steam required in relation to electric
How
power result in higher plant efficiency 7
Co‐generation systems without steam turbine
Process Process
Steam of
Steam of Steam of
Steam of
E 10 bar E 10 bar
C d
Cond. return C d
Cond. return
However high efficiency is
not always economic.
g y
In co‐generation systems
deletion of steam turbine
and a low pressure boiler
could be more economic
could be more economic.
• special in smaller units 8
Impact of boiler pressure
p p g p
on power output in co‐generation plants
120
100 bar/539
37% more
100 power
E 100 t/h , 80
85
85 bar/516 C
bar/516 C
2 barg, 143 C 30% more
power
Process steam Pressure 60
(Bar)
Cond. Return with 125 C
d h 66 bar/486 C
66 bar/486 C
40 17% more
power
fuel 45 bar/430 C
E 100 t/h , 20
2 barg, 143 C
E Process 0
steam 0 2000 4000 6000
Cond. Return 125 C Additional Power (KW) with efficiency of approx 86%
for biomass/coal and 94% for gas fired 9
Same applies also when more and more power is generated in
combination of backpressure and condensing steam turbine
E E
50 t/h 50 t/h
E
10
In combined cycles with only power generation it is different.
4300 Power (Kw)
Additional
4250 Power (KW) 4253
4239
4228
66 Bar /
500 C
E 4200 45 Bar / 449°C
85 Bar / 449°C
428°C
4160
4150
E 30 Bar /
400°C
4100
4050 4053
20 Bar / 394°C
Bar / 394 C
4000
0 20 40 60 80 100
Pressure (Bar)
p p
•When GT exhaust temperature 500 C then a pressure between
30 and 45 bar would be optimal.
•How lower this temperature how lower the pressure.
•How higher this temperature how higher the pressure
•How higher this temperature how higher the pressure.
•For large gas turbines double or triple pressures are more
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economic.
Impact of steam temperature
on power output
on power output
in simple cycle co‐generation plants
This process steam should
E
not be wet
not be wet.
10 t/h
Should be 10 C overheated.
Therefore take HP steam
Process 100 t/h ,
temperature high enough. Cond. Return steam 2 barg, 143 C
ie
i.e.
•At 45 bar min. 430 C
•At 66 bar min. 486 C
At 85 b i 516 C
•At 85 bar min. 516 C
• At 100 bar min. 539 C
12
•Higher HP steam temperature will give more output
•i e increase at 66 bar from 486 C to 500 C
•i.e. increase at 66 bar from 486 C to 500 C
•result in 0,8% more power output ( by firing additional fuel with
efficiency of 86%).
h f ll d l (b f dd lf l h
•When full condensing result in2% (by firing additional fuel with
efficiency of 30 till 35%).
However higher temperatures E
10 t/h
/h
means
Selection of higher alloy/more
expensive materials
expensive materials
Is this economic? Process 100 t/h ,
Cond. Return steam 2 barg, 143 C
13
Feed water preheating
When only process steam supply :
yp pp y
How much more E‐power in case of preheating
with adding additional fuel:
2e stage: E
At 100 bar 4,7% more
A 65 b 2 9 % more
At 65 bar 2,9 %
With efficiency of approx Process steam
2barg, 143 C
45% on fuel input.
Economic?
Cond. Return with 125 C
1e stage:
1 t
At 100 bar 5,8 % more
At 65 bar 5,4 % more
With efficiency of approx 52%
on fuel input. 14
When no process steam supply/ only condensing :
How much more E power in case of preheating
How much more E‐power in case of preheating
without adding additional fuel:
E
2e stage:
At 100 bar 1% more
At 100 bar 1% more
At 65 bar 0,6% more
Economic?
1e stage:
At 100 bar 2% more
At 65 bar 1,7% more
,
15
Effect cogeneration on steam turbine selection
HP steam pressure control Backpressure control for
by steam turbine controlling LP steam pressure
Requires minimum flow
Requires minimum flow
E
of approx 10% of design flow.
NOTE:
Steam turbines should be selected
very accurate.
y
The normal and maximum steam
Process 100 t/h ,
Cond. Return steam 2 barg, 143 C flow should not deviate much.
Otherwise low efficiency of steam
Otherwise low efficiency of steam
turbine.
Specially for condensing part. 16
Each system is unique in steam and electric
requirement.
A feasibility study is always required before deciding
A feasibility study is always required before deciding
for the most economic solution.
1. What are the maximum, normal and minimum
steam and power requirements.
2. What are the operating times
p g
3. What should be the availability
4. Do not use steam turbine driven equipment
because there efficiency will be always much lower
because there efficiency will be always much lower
then with the power generating equipment.
5. Use electric driven equipment.
6. For large power consumers use variable speed
l bl d
control drives. 17
Boiler water and steam requirements
Availability of the plant depends how the water and steam
f
conditions are maintained.
It is recommended to use demi‐water as make‐up and to polish
the return condensate when its quality is not guaranteed.
The dosing of chemicals in the feed and drum water should be
controlled automatically to ensure compliance.
In line instrumentation is required to maintain the required
li i i i i d i i h i d
qualities within a certain band.
y
Maintenance of system is essential.
A Lab is needed to collect daily a samples to check the accuracy of
the daily dosing and analyzing equipment
the daily dosing and analyzing equipment.
The chemicals should be supplied by reliable suppliers. 18
Biomass Fuels in Pakistan
1. Bagasse All those fuels have common:
2. Sugar cane Trash •High Volatile content
3
3. C
Corncobs
b •Nett Heating value on basis of ash and
4. Rice husks water free all approx the same (17,8 till
5. Cotton Stalks 19 MJ/kg)
9 MJ/kg)
6. Wheat straw
7. Wheat rice
NOTE:
Fuels are different in: • The composition can vary per
• moisture content season and per area.
•Ash content • It is necessary to send fuel to lab
It is necessary to send fuel to lab
• Alkali content in ash for analysis
• Sulfur • The fuels can be fired on different
• Chloride stoker types and in fluidized bed
k d i fl idi d b d
• density system.
19
Local coal
• Known analysis of mines in Makarwal Area only
• It is a high volatile B bituminous coal
• Moisture content 5 till 10%
• The sulfur content is very high 7,1 wt% on dry.
• Ash content varies from 15 till 25%
Ash content varies from 15 till 25%
• The initial deformation temperature is unknown (first melting point
of elements in ash). )
• Softening temperature is 1020 C
• The quality of coal is not consistent
• The coal supplied needs to be analyzed before firing it.
• Due to higher sulfur content and expected variation in ash content
the local coal needs to be fired in a fluidized bed system
the local coal needs to be fired in a fluidized bed system.
• To handle the variety in composition we recommend a bubbling 20
fluidized bed
21
22
Imported coal
Imported coal
• High quality coal is supplied from Indonesia, South Africa and
g q y pp ,
China
• It is a high volatile A bituminous coal
• Moisture content 10 till 20%
• ash content 5 till 15%
• Low sulfur content 0,4 till 0,8%
Low sulfur content 0 4 till 0 8%
• High initial deformation temperature, above 1200 C.
• Can be fired on travelling grate and in fluidized bed.
Can be fired on travelling grate and in fluidized bed
23
Characteristics of biomass and coal
60 0
60.0
52
50.0
40 0
40.0
30 29
30.0 25
20.0 18 18.5
15 15 1513 15 16
6
1111.7 1113 12 10
10.0 8.4 8 7 8 7.0
4.4 5.7
2 2.5
0.0
Moisture Content % LHV(MJ/Kg)
/ Ash
24
Prices of biomass and local coal per kg and per MJ
Prices of biomass and local coal per kg and per MJ
• Prices are mostly related to weight
y g
• However more realistic is to relate to energy on lower heating
value (LHV).
• The properties of biomass fuel can differ per area and year. It
is important to verify the properties of biomass by a proper
test procedure.
p
• The same applies for local coal
25
Prices of Biomass & Coal
P i (R /K )
Price (Rs/Kg) P i (R /MJ)
Price (Rs/MJ)
0.40 0.37
0.35
0.30
12.0
12 0 11 0 30
0.30 0 27
0.27
10.0 0.25 0.21
8.0 0.19
0.20
6.0 5.3
0.15
4
4.0 3 0.10
2
2.0 0.05
0.0 0.00
Price (Rs/Kg) Price (Rs/MJ)
The local coal is very competitive in relation to biomass fuels.
The local coal is very competitive in relation to biomass fuels.
As biomass fuels are environment friendly they need more stimulation.
i.e. carbon credits, positive effect on taxes, etc. 26
Effect of fuel on logistics
Effect of fuel on logistics
• Compared to coal biomass has lower density.
p y
• More volume to handle in transport, storage and feeding
system.
• Biomass is not physically homogeneous and free flowing.
Difficulties in transportation, metering , storage and feeding
• During storage the fuels will deteriorate. Bagasse
During storage the fuels will deteriorate Bagasse is of the
is of the
easiest ones to decompose. It can reduce to half it LHV value
within one year of storage.
27
Effect on fuel handling for solid fuels
25,000 23,780
20,336
20,000
LHV(MJ/M³)
( )
15,000
10,000
28
Effect of fuel on ash handling
Ah
Ash content (Kg/Gj
t t (K /Gj)
18.00
16.00
14.00
12.00
10.00
8.00
6.00
6 00 Ash content (Kg/Gj)
Ash content (Kg/Gj)
4.00
2.00
0.00
29
Environment
• Biomass is a renewable energy which does not increase the CO2 level. CO2
credits will give a cost saving
• Due to high volatile content the NOx levels with biomass firing are low
• Sulfur emissions are nil. Local coal has high sulfur content and require fluidized
bed combustion with limestone injection to keep Sox emission low.
• Sulfur dioxide emission requirement for fossil fired boilers is unclear.
• For local coal limestone has to be injected in bed for binding the sulfur. Normally
l l l li h b i j d i b d f bi di h lf ll
80% of sulfur is bonded with limestone This will increase the total ash content
with approx 60%.
• The requirement of limestone makes the local coal approx 15% higher in price.
30
Selection of firing and boiler system
Selection of firing and boiler system
Fuels are different in: What are the
A. moisture content effects on selection
B. Ash content and its properties
Ash content and its properties
C. Sulfur of firing and boiler
D. Chloride system?
31
A. Moisture content
•High moisture means that the water have to be evaporated first.
•This requires preheated air supply. This requires an air‐pre heater at outlet of
boiler.
•i.e. Bagasse of 52% moisture content requires 220 till 260 C air temperature.
•In case of low moisture content the air‐preheating should be limited in order to
avoid overheating of stoker system.
•How higher the moisture content how lower the boiler efficiency
Higher moisture content results in higher flue gas velocities in boiler which
•Higher moisture content results in higher flue gas velocities in boiler which
causes more erosion.
g
•Lower moisture content in Bagasse from 50 to 40% results in approx 1,8% higher
pp , g
efficiency and 15% less flue gas velocities.
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B. Ash content
When low ash content of 2 till 4% and high volatile biomass
fuels are used then a stationary stoker type can be used. Also
called pinhole grate
called pinhole grate
Steam nozzles for cleaning the
grate
Cast iron elements
attached and cooled by the
tubes
Water cooled tubes as
part of boiler system
33
Dumping grate is not recommended as it will give:
• an interruption in steam supply during cleaning
i t ti i t l d i l i
• much higher unburned losses
• more interruptions due to overheating of grate bars
In other cases with ash contents up to 20% a travelling grate is
recommended.
34
How higher the ash content how more erosion in the boiler.
S i ll h
Specially when silica content is very high.
ili t ti hi h
How higher the ash content how larger the boiler will be.
Rice husks has extremely high silica content of 96% and suffer
from considerable carry over of material into the convection
from considerable carry over of material into the convection
banks.
The allowable velocities are more then 50% less then for other
bi
biomass fuels and coal. This results in a much larger boiler then
f l d l Thi lt i hl b il th
normally seen for other kind of fuels.
Further a travelling grate will have also a high wear and tear due
to this ash.
35
As the rice husk will be fired mainly in
suspension and the ash will leave the
and the ash will leave the
furnace mainly as fly ash a water cooled
inclined grate system is very suitable.
The grate is then protected from over firing
by the water cooled grate system.
This grate is normally used for a very wide
g y y
range of fuels and low ash contents.
The ash of rice husks is transforming from amorphous state to
crystalline state when it is exposed to temperatures above 850
C In a fluidized bed system this can be avoided
C . In a fluidized bed system this can be avoided.
The ash can then be easily used in steel mills and other
applications.
With fl idi d b d t
With a fluidized bed system the wear and tear problem is
th dt bl i
minimized.
36
Bagasse and imported coal can be fired simultaneously on a
and imported coal can be fired simultaneously on a
travelling or vibrating grate.
Th
The maximum amount of coal is however restricted.
i t f li h ti t d
When this would be too high the local firing temperatures get
too high and the ash of the bagasse would clinker and cause
problems on the grate and fouling in furnace and heating
surfaces.
surfaces.
With the other fuel mixtures similar limitations are there.
37
C. Chlorine, sulfur and ash characteristics
The ash characteristics of fuels are important.
Specially important are:
• the alkali metals (Ca, Na, K) are important.
• silica
Further the sulfur and Chlorine content in the fuel is an
i
important factor
f
Those contents needs to be verified in the lab before deciding
g
the best combustion and boiler system.
38
Elements in biomass & coal potentially
leading to corrosion and deposits
leading to corrosion and deposits.
8.00
7.1
7.00
6.00
5.00
4.00
3 00
3.00 2.44
2.22
Sulphur (S)%
Chlorine (Cl)%
Chlorine (Cl)%
K+Na%
39
Those elements determine the clinkering, slagging
and fouling and also the erosion and corrosion
potentials of the fuels.
A range of indices are available to assist in predicting
those potentials.
Also test are required to determine the following
conditions in the lab of the ash at high
temperatures:
• initial deformation temperature
• sintering temperature
g p
• hemispherical temperature
• Flow temperature
Those tests will also assist in predicting the
40
clinkering , slagging and fouling potential of the fuels
The potasium (K) salts (KCl and KOH) become volatile above
650 C and deposition downstream can cause serious
corrosion and fouling.
For that reason the flue gasses will be cooled down in water
For that reason the flue gasses will be cooled down in water
cooled cavities till 650 C when the indices indicates this
potential problem.
We recommend to fire fuels with high (Ca, Na, K) contents in
a fluidized bed system as the combustion temperature in the
bed and free board are low and can be controlled more.
The biomass fuels are:
• cotton stalks
• sugar cane trash
• corn cobs
• Wheat straw and rice straw
Wheat straw and rice straw
41
Those can be fired in combination with the local coal.
The ratio of sulfur to chlorine indicates if corrosion can be
expected in the superheaters. If Chlorine is much higher in
content then the superheater tube metal temperature
needs to be kept low (maximum 450 C).
needs to be kept low (maximum 450 C).
Or inconel tubes should be used when higher steam
temperatures are required.
The sulfur content is also an indication for the sulfur
dewpoint of the flue gasses. The water inlet temperature of
economiser and also the tube metal temperature of the air
pre‐heater should be kept above this temperature in order
to avoid sulfur corrosion.
42
Furnace and over firing system
Furnace and over firing system
In order to optimize the firing process
of the system it is important to size the
of the system it is important to size the
furnace correctly.
IImportant factors are:
t tf t
• furnace liberation rate
•Excess air
•Amount of under grate and over firing
air amounts
Flue gas speed
•Flue gas speed
•Correct installation of over firing
system
•Residence time
•Residence time
•Furnace flue gas outlet temperature
43
44
All those factors will determine the unburned content at
outlet of furnace and the condition of the fly ash
outlet of furnace and the condition of the fly ash.
The fly ash should not be sticky at outlet of furnace in order
to avoid heavy fouling of the super heater area
The tubes in the boiler convection section will be arranged
g
in line and in between the tubes sufficient distance will be
kept in order to minimize the fouling.
By adequate steam soot blowing the surfaces will be kept
clean.
The dust collected in the hoppers and cyclones' will be re‐
j p j
injected in the furnace on several points just above the
grate into the furnace to lower the unburned to 50%.
45
So, be aware:
For designing the most appropriate firing and boiler
system the range of fuels have to be determined in
advance and lab test should be made available.
Then we can supply a system which will be in
pp y y
compliance with your requirements in steam and
power supply, availability and reliability of the system.
For ensuring high efficiencies, reliability and the
capability to fire a large range of biomass and coal for
its life time we recommend a bubbling fluidized bed
lf d b bbl fl d d b d
system.
Thank You For Your Attention
46