Gliwice, November 22, 2005

1. Andrzej Ziębik Institute of Thermal Technology, SUT Combined Heat and Power ITT experience in Coal Technologies Gliwice, November 22, 2005

2. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Institute of Thermal Technology Silesian University of Technology Divisions: Division of Thermodynamics and Gas Energy Division of Energy Management and Refrigeration Division of Combustion Technologyand Internal Combustion Engines Division of Heat Transfer, Nuclear Engineeringand Renewable Energy Resources Group of Computer Methods in Thermal Engineering • Staff: • - 11 full professors • - 3 associate professors • - 17 assistant professors • 26 masters of science • (assistants, PhD students) • Selected activities: • exergy – theory and practice • cogeneration • simulation and optimisation of power units • numerical heat transfer • computational fluid dynamics • HTAC (High Temperature Air Combustion)

3. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Institute of Thermal Technology – selected books

4. Andrzej Ziębik Combined Heat and Power, ITT experience Control Systems of Operation of Power and CPH Units Optimization of the Application of gas and steam CPH Plants in Polish Industial Investigation of the Combustion Processes in Highly Preheated Air Optimization of Energy Management of Industrial Furnaces Coal Mine Gas from Abandoned Mines in Upper Silesian Basin Gliwice, November 22, 2005 Polish – German scientific network1997-2003 TU Berlin TU Clausthal UMSICHTOberhausen Gliwice INternational Cooperation on Research in EnvironmentAl protection, process Safety and Energy Technology

5. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Centre of Excellence OPTI_Energy (V Framewrok Progamme of European Commission) Optimization, simulation and environmental impact of energy systems and processes 2003 - 2006 • summer schools • international conferences • international workshops for PhD students • seminars for the industry

6. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 INTRODUCTION TRADITIONS OF CO-GENERATION IN POLAND • First back-pressure steam turbine – 1939 • After the second world war –repowering of pre-war power stations – condenser operating in a deteriorated vacuum as the first stage ofpreheating the district heating water • 60’s – 70’s • CHP’s equipped with special bleed-condensation and back-pressureturbines

7. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 The latest 20 years  • CHP’s with heating units   • Heating units with fluidisation boilers • Power units adapted to district heating purposes • Some medium- and small-scale CHP’s fired with natural gas • Industrial CHP’s fired with hard coal and technological fuel gases or liquidwaste fuels • Fundamental fuel in Polish CHP’s- hard coal

8. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 The share of electricity produced in district heating and industrial CHP’s 19 % (together with the condensing part)  15 – 16 % (only co-generation)  Production of electricity in CHP’s = 27.5 % Production of heat in CHP’s

9. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005

10. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Unit 1 Unit 3 and 4 Unit 2

11. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005

12. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 INDUSTRIAL CHP’s – SPECIFIC PROBLEMS Short statistical information  Power rating – 3 GWel (~9 % of global power rating of NES) The share of electricity production in global national demand 5 ~ 5.5 % (in co-generation – 4.5 %) The largest industrial CHP 300 MWel

13. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 COAL&STEEL PROBABILISTIC APPROACH TO THE DETERMINATION OF THE OPTIMAL STRUCTURE OF A METALLURGICAL CHP FIREDWITH TECHNOLOGICAL FUELGASES Repowering of traditional CHP by realization of gas and steam cycle Net present value of modernisation of CHP plant

14. Andrzej Ziębik Combined Heat and Power, ITT experience Ambient temperature duration curve Fuel supply Design Optimization Simulation Gliwice, November 22, 2005 COAL&STEEL CHP system integrated with metallurgical process Corex The Corex process: coal gasification • District heat demand: • ironworks, • nearby city. Pig iron and export gas Production. Process steam demand: 0.6 MPa, 270OC

15. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 COAL&STEEL CO2 Removal from Corex Export Gas 5,2% CO2 62,2% CO 26,7% H2 11300 kJ/m3n The COREX process The CO2 removal process (physical absorption with the Selexol solvent) 35% CO2 42% CO 18% H2 7600 kJ/m3n

16. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 COAL&STEEL • Characteristic features: • production of pig-iron in • big amount • high exergy efficiency • basic fuel – coke • (rather high thermoecological cost) Blast furnace process Main purpose of rationalization of energy management of blast-furnace plant decrease of coke consumption • Ways of rationalization • injection of pulverized coal as auxiliary fuel • increase of blast temperature • enrichment of blast with oxygen • increase of top gas pressure

17. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 COAL&STEEL Blast furnace process Thermoecological cost Energy indices

18. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Biomass co-firing – ITT and Power Plant „Opole” • Impact on boiler and overall plant efficiency • simulation analysis for existing big power units Method for calculation of „green” energy production Net power unit efficiency Moisture content in biomass, %