Flexibilität mittels hocheffizienter Technik

Transcription

1 Flexibilität mittels hocheffizienter Technik Wolfgang Schreier, Dr.-Ing. Roland Jeschke, Dr.-Ing. Björn Henning

2 Outline Special situation in Germany What does flexibility mean for power plants Residual load Plant efficiency at full & part load / ramp rates Means to improve power plant flexibility Firing system Gas turbine repowering Conclusion Hitachi Power Europe GmbH 2 2

3 NIMBY, BANANA etc. The attitude of the German population towards the issue/ acceptance of technical facilities to be build has recently developed from NIMBY to BANANA Not In My Backyard now uild bsolutly othing nywhere The complexity of approval procedures and the lack of planning reliability for newly build power plants can be observed not at least at the Datteln 4 project. A possible solution is the replacement of existing obsolete plants in the respective location, this may result in new plant constructions inside existing structures. ear nyone 1 Example for this solution: Malmö ancient oil and coal boiler to CCGT conversion Hitachi Power Europe GmbH 3

4 New plant constructions - Conversions In contrast to designing a power plant on a greenfield site New plant constructions inside existing structures conversion from to coal gas oil inside existing structures Hitachi Power Europe GmbH 4

5 Oeresundsverket, Malmö, Sweden ancient oil and coal boiler to CCGT conversion Fuel: Oil - Year of Commissioning: 1953 Fuel: Coal - Year of Commissioning: MW Combined Cycle Power Plant Gas Turbine: 1 x GE 9FB 293 MW Steam Turbine: 1 x Extraction/Condensing Type 161 MW Fuel: Natural Gas - Year of Commissioning: 2009 Hitachi Power Europe GmbH 5

6 Hitachi Power Europe GmbH 6

7 load (GW) Situation and further need/expectations 2010 to 2020 load (GW) Net load February 2010 Net load May TWh (per month) TWh (per month) Time 0 Time total load conv. power stations + storage i.e. residual load Photovoltaik Wind Onshore DENA Wind Offshore DENA CHP feed-in water power P min 27 GW P max 62 GW P min 10 GW P max 57 GW Hitachi Power Europe GmbH 7

8 What does flexibility mean for coal fired power plants? Requirement / Task Actual Target Extension of load range below 35% with oil- or gas support fire below 15% without cost intensive fuels Expected ramp rate approx. 5%/min ~ 10%/min Frequent start up and shut down ability (cold/warm/hot) Emissions and plant efficiency must be kept during part load Possibly daily start up Design for high efficiency at full load Possibly daily change between <15-100% To avoid daily start up Design for high efficiency in part load regime 8 Hitachi Power Europe GmbH 8

9 State of the art Plant Efficiency Relative Plant Efficiency (%) 100 coal fired plant combined cycle gas turbine Load (%) Hitachi Power Europe GmbH 9

10 State of the art Levelized Cost of Electricity /MWh Hard coal ,3 29,7 5,5 13,2 41,8 2,75 9,35 CCGT Ratio 1 / 2 Fuel cost 2 / 1 Opex 3 / 2 Capex 10 Hitachi Power Europe GmbH 10

11 State of the art Plant Efficiency Relative Plant Efficiency (%) 100 coal fired plant 95 Change in fuel cost (%) combined cycle gas turbine combined cycle gas turbine coal fired plant 5 Stronger increase of fuel costs Load (%) for gas fired PP compared to coal fired PP at part load Hitachi Power Europe GmbH 11

12 State of the art rate of load change in % P max /min % Load Rate of load change of fossil power plants in %/min at load-dependent mode of operation New Units Lignite & Hard coal Hard coal old 7 %/min 3 %/min 2 %/min Lignite old time [min] Hitachi Power Europe GmbH 12

13 State of the art rate of load change in MW/min MW MW/min Rate of load change of fossil power plants in at load-dependent mode of operation New Units, 1000 MW 30 MW/min 20 MW/min 35 MW/min Hard coal old, 1000 MW Lignite old,1000 MW CCGT, 600 MW time [min] Hitachi Power Europe GmbH 13

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15 Means to increase flexibility Turbine GT Repowering Boiler Line arrangement (from 2 to 4 lines) Increase the number of headers/ separators Increase Design parameter the number for of components headers/ separators (preheating) Firing System Indirect / combined firing DS-T Burner Hitachi Power Europe GmbH 15

16 Indirect firing Cyclone Raw coal bunker Dust bunker conveyer Air Feeding System Burner Direct Firing Indirect Firing classifier Minimum load coal firing % <10 % Mill Ventilator Consumption of support fuel during cold start 100 % 5 % Excess air 15 % <12 % Milling process Normal operation: coal mills in part load optimal operation range Hitachi Power Europe GmbH 16

17 DS-T Burner The flexible DS-T Burner hard coal sawdust dry lignite Example: 15% load (e.g. ~2,8 l/s light fuel oil = ~1 100 MW start up, minimal- and light load WITHOUT costly support fuels! 17 Hitachi Power Europe GmbH 17

18 Means to increase flexibility Turbine GT Repowering Boiler Line arrangement (from 2 to 4 lines) Increase the number of headers/ separators Increase Design parameter the number for of components headers/ separators (preheating) Firing System Indirect / combined firing DS-T Burner Hitachi Power Europe GmbH 18

19 Line arrangement & increase number of separators / headers Allow. temperature change rate [K/min] Reduced wall thickness 2 line to 4 line design leads to reduction with Factor 0,707 of header wall thickness increase the number of separators/ headers use of superior materials, e.g. A617 instead of P Header Di=180mm 10% Design 4 7% Design Possibility 10 % load change Pressure/P nom [%] Hitachi Power Europe GmbH 19 19

20 Optimization for part load operation Reduction of auxiliary power, speed controlled Fans Power requ. shaft [kw] Standard Spec. Full load optimization Part load optimization variable speed control Load [%] Example: 800 MW, 40% Load 40 % (SG: 94,5%) S: + 0,25 % 40% Part load 20 Hitachi Power Europe GmbH 20

21 Means to increase flexibility Turbine GT Repowering Boiler Line arrangement (from 2 to 4 lines) Increase the number of headers/ separators Increase Design parameter the number for of components headers/ separators (preheating) Firing System Indirect / combined firing DS-T Burner Reduction of auxiliary power Hitachi Power Europe GmbH 21

22 Repowering Matra, Hungary More Efficiency, More Power 2 x 212 MW el Lignite Boiler Supplemented by Gas Turbine: 2 x Hitachi H-25AX 30 MW el Power Increase Lignite B.: 20 MW el Total El. Power Increase: 100 MW el Fuel Utilisation: 90.3 % Fuel: Natural Gas Year of Commissioning: 2006 Hitachi Power Europe GmbH 22

23 Repowering Feedwater preheating by Gasturbine Existing Power Plant G Repowering G Gas turbine(s) HP recovery preheater LP recovery preheater Hitachi Power Europe GmbH 23

24 Repowering the future More Efficiency, More Power for the Reference Power Plant NRW (RPP NRW) Efficiency (%) GT + 2 GT single coal unit (RPP NRW) Load (%) More Efficiency More Power Hitachi Power Europe GmbH 24

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26 Conclusion [%] Minimum Load Ramp rate [%] Cyclone 10 0 [ %] [ %] [ %] DS-Burner DS-T 100% Biomass capable Conveying nozzle Dust bunker Rotaryfeeder Air Raw coal bunker 0 Power Output Conveyer Classifier Plant Efficiency -30 CO2 Emissions Mill G Fan Reduced GT Indirect DST-Burner Repowering firing wall Retrofit thickness & Increase number Combine existing technologies reasonable to improve flexibility! of separators/headers Hitachi Power Europe GmbH 26

27 Conclusion Available technology to improve flexibility is not used or is not known? High ramp rates in MW may be delivered by big units cost-efficiently. Technology to improve flexibility is already available is there a market? Hitachi Power Europe GmbH 27