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Latest technologies Pathway to USC NRW Reference Plant and 700°C Power

Latest technologies Pathway to USC NRW Reference Plant and 700°C Power. Dipl. Ing. Werner Hartwig 09.09.2008. Project Co-ordination. Scientific Accompaniment Chair for Energy Economics, Univ. Essen Institute for Climate, Environment and Energy, Wuppertal

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Latest technologies Pathway to USC NRW Reference Plant and 700°C Power

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  1. Latest technologiesPathway to USC NRW Reference Plant and 700°C Power Dipl. Ing. Werner Hartwig 09.09.2008

  2. Project Co-ordination Scientific Accompaniment Chair for Energy Economics, Univ. Essen Institute for Climate, Environment and Energy, Wuppertal Rhineland-Westphalian Institut of Economic Research, Essen Steering Committee Manufacturer, Power Supply Industry Regional GovernmentCoal Mining Industry PowerSupply Industry Manufacturer Reference Power PlantNorth Rhine-Westphalia (RPP NRW) |

  3. Reference Power Plant NRW |

  4. Design Coal RPP NRW Fuel Range Heating Value MJ/kg 25.0 21.0 – 29.0 H2O % 7.5 7.0 – 18.0 Ashes % 14.0 5.0 – 22.0 Volatiles (waf) % 30.0 23.0 – 47.0 Nitrogen % 1.5 < 2 Sulfur % 0.6 < 1.5 Chlorine % < 0.01 < 0.3 Softening temperature °C 1270 > 1150 Fusion temperature °C 1410 > 1300 |

  5. Main Criteria for technical economicalOptimization “Situation on GermanPower Wholesale Market in 2004” Production costs Average wholesale price |

  6. Assessment Factors for Power Plant Design Efficiency of power plant (15.5 Euro/kW or 9.3 Mio. Euro per percentage point of efficiency improvement) Reduction of power plant own consumption(17.4 Euro/kW or 10.4 Mio. Euro per percentage point of own consumption) Plant availability(13.1 Euro/kW 7.9 Mio. Euro per percentage point of power availability improvement Reduction of delivery time2.7 Euro/kW or 1. 6 Mio Euro for 1 month of delivery time reduction |

  7. Calculation of Assessment Factor Efficiency of power plant 15.5 Euro/kW or 9.3 Mio. Euro per percentage point of efficiency improvement) Basis: Eff.: 44% -> 1000 €/kW -> CoE =3.577 C/kWh (First Estimation) Increase of Efficiency 44% -> 45% Increase of Investment to reach same CoE Difference in Investment = Evaluation Factor for Efficiency |

  8. Efficiency vs Assessment Factor *) |

  9. 48.50% non-market orientatedtechnological optimized plant(costal side) 48.00% 47.50% market orientated optimised plant(costal side) Net Efficiency 47.00% 46.50% market orientated optimised plant (non-costal side) 46.00% 45.50% Efficiency of Hard Coalfired Power Plants vs Site |

  10. Floor space: 4 164 m² Volume: 197 000 m3 Efficiency: 95% Floor space: 4 600 m² Volume: 209 000 m3 Efficiency: 95% Floor space: 2 975 m² Volume: 166 000 m3 Efficiency: 95% Comparison of different Boiler Concepts |

  11. VGB Horizontal boiler Burner: 24 Coal pulverizer: 4 Coal mill with hydraulic system and Coal pulverizer Number of burner and pulverizer0 |

  12. Design Data Turboset |

  13. Design Criteria HP-Turbine |

  14. HP Turbine Materials |

  15. Design Criteria IP-Turbine |

  16. MP Turbine Materials |

  17. Design Criteria LP-Turbine |

  18. LP Turbine Materials |

  19. 2 Design features 16 m - last stage blade • Rotor diameter ~ 1900 mm • Blade length 1400 mm (55´´) • Velocity at blade end 750 m/s (~ Ma = 2.0) • Mach - number Supersonic at blade end • Blade connection Shroud & snubber • Exit losses 3D effects LP Turbine Features |

  20. |

  21. Turbogenerator |

  22. Layout - Overview |

  23. Layout – Detailed View |

  24. Detailed View – Turbine Building |

  25. Main Flows |

  26. Market - Orientated OptimizedPower Plant Design (Reference Power Plant North Rhine-Westphalia) • Plant capacity: 600.0 MW • Net capacity: 555.5 MW • Net efficiency: 45.9 % • Costs of plant: 478.5 Mio. Euro • Specific costs: 798 Euro/kWbrutto • Cost of electricity: 3.3 - 3.5 ct/kWh • Type of boiler: Benson • Live steam condition: 285bar/600°C/620°C • Condenser pressure: 45 mbar • Preheater: 8 preheater + external cooler |

  27. |

  28. 0.6 ct/kWh 0.5 ct/kWh 0.4 ct/kWh 0.3 ct/kWh 0.2 ct/kWh RPP NRW more profitable in relation to CCPP 0.1 ct/kWh 1.0% 0.0 ct/kWh 0.5% 0.0% -0.5% -0.1 ct/kWh -0.2 ct/kWh -0.3 ct/kWh Escalation of coal price 0.5% escal. gas price 1.0% escal. gas price 1.5% escal. gas price 2.0% escal. gas price Comparison of profitability RPP/CCPPplant without costs for CO2 |

  29. RPP NRW more profitable in relation to CCPP 0.2 ct/kWh 0.1 ct/kWh -0.5% 0.0 ct/kWh 0.0% 1.0% 0.5% -0.1 ct/kWh -0.2 ct/kWh -0.3 ct/kWh -0.4 ct/kWh -0.5 ct/kWh -0.6 ct/kWh -0.7 ct/kWh Escalation of coal price 1.5% escal. gas price 1.0% escal. gas price 2.0% escal. gas price 0.5% escal. gas price Comparison of profitability RPP/CCPPwith Costs of 10 € t/CO2 |

  30. Pathway to USC 700°C Power Plant USC 700°C Power Plant Laboratory (material development, creep data) Tests in power plants (Test Rigs, COMTES700) Site, supplier, erection Basic and detail design (NRWPP700) European and German projects 2007 1998 2014

  31. Pahtway to USC 700°C Power Plant Status 700 °C Technology • AD 700 phase I and II (FP5) 1998 • strategy study (VGB member) 2002 • COMTES 700 (RFCS) 2004 • PP700Pre-Engineering (EUReg. Fund)2006 • Demo Plant > 400 MWel 2008 • “Commerciality” 2014+ Start in

  32. Pathway to USC 700°C Power Plant …targeting the 50% threshold by achieving 700 °C steam parameter • Scholven, Block Power Plant.EU-funded Project and Industry. • Testrigs in Esbjerg u. Weisweiler, KOMET650 in Westfalenown financial contribution • Technology Path towards • near Zero Emission Power Plants based on fossil Fuels • a permanent challenge of all participants in close co-operation

  33. 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: 45-46% Efficiency 700°C Technology: 50% Designed by Hitachi Power Europe

  34. COMTES700 – Implementation into Boiler • Host Plant - Scholven F, E.ON • Net output • 676 MW • Live-steam • 220 bar (design pressure) • 540 °C • 625 kg/s (2,250 t/h) • Reheater-steam • 44 bar • 540 °C • 568 kg/s (2,044 t/h) • Fuel • Hard coal Superheater Evaporator

  35. COMTES700 – Material Concept Evaporator VGB Power Tech

  36. 700 °C Steam Pipe

  37. Boiler Design - NRWPP700Boundary Design Conditions • 500 MW (gross) BMCR • Single Reheat (365 bar / 705 °C / 720 °C) • Tower Type Boiler / Tangential Firing

  38. ECO RH 1 SH 3 RH 2 SH 4 SH 2 PL Boiler Design - NRWPP700Boiler Design Data at Load Steam flow superheater outlet 325 kg/s (1170 t/h) Steam pressure superheater outlet 365 bar Steam temperature superheater outlet 705 °C Feedwater temperature 330 °C Reheater inlet steam flow 252,5 kg/s (909 t/h) Reheater inlet steam pressure 73 bar Reheater outlet steam temperature 720 °C Reheater inlet steam temperature 425 °C Reheater spray mass flow 0 kg/s Thermal output 909 MW Design coal Bituminous coal (25 MJ/kg) Excess air furnace exit 17 % Firing capacity 953 MW Furnace exit temperature 1250 °C Flue gas temperature downstream economizer 380 °C Flue gas temperature downstream airheater 115 °C Maximum flue gas velocity in convective heating surfaces 9,3 m/s

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