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Neurath F and G set newbenchmarks

Also referred to as BoA 2 and 3, RWEs Neurath units F and G set a benchmark for lignite fuelled power stations. The new Neurath

units use and build on the BoA package of advanced optimised lignite technologies first employed at Niederaussem. They will have

a gross capacity of 1100 MW each and a net efficiency of over 43%.

Under the contract, Alstom is carrying out the overall power plant engineering. Alstom is also supplying, erecting and

commissioning the two steam turbine islands, including condensers, and in consortium with another company, delivering two

steam generators.

A key rationale for building the two new units is achieving a reduction in CO2 emissions, via increased thermal efficiency: this stems

from having the largest lignite fired boilers in the world, with the most advanced steam conditions ever achieved for lignite; an

advanced steam turbine with titanium last stage blading, coupled to the highest rated two-pole generator yet built; nine-stage

feedwater preheating; waste heat recovery from the flue gas; and optimisation of auxiliary power needs.

June2008

Neurath

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LIGNITE POWER

Also referred to as BoA 2 and 3, RWEs Neurath units F and G 1100 MWe

gross each with efficiency over 43% use and build on the BoA package

of advanced optimised lignite technologies first used at Niederaussem. Contributors to the high efficiency

include: the largest lignite fired boilers in the world, with the most advanced steam conditions ever achieved

for lignite; advanced steam turbine with titanium last stage blade, coupled to the highest rated two-polegenerator yet built; nine-stage feedwater preheating; waste heat recovery from the flue gas; and optimisation

of auxiliary power needs. A key rationale for the new units is the replacement of old, less efficient, units,

leading to a significant reduction in CO2 emissions, by some 6 million t/y compared with the emissions that

would be produced by the older units in generating an equivalent amount of electricity.

In June 2005, the Dsseldorf regionalgovernment gave its approval for theconstructionand operationat theNeurathsiteof two lignite-fired power plant units

employing optimised plant technology (BoA).

TheNeurathfacilities willbe thesecond and thirdBoA units (BoA 2 and 3, after BoA 1,

Niederaussem, which went on stream in 2003).

The two power plant units will have a grosscapacity of 1100 MWeeach(1050MWe net) anda net efficiency of over 43%, similar to that of

Niederaussem.The most striking features of the Neurath site

are the two 170 m high buildings for the steamgenerators(boilers), which willlook muchlikethe

Niederaussem unit, and the two cooling towers.

Neurath F and G setnew benchmarks

Reinhold Elsen,

RWE Power, Essen,Germany and

Matthias Fleischmann,

Alstom, Mannheim, Germany

GERMANY

CologneAachen

FrankfurtMainz

Dsseldorf

Theexisting Neurath plant,left,and, right,

visualisation of thenew units,F andG

Location of Neurath

Frimmersdorf,150 MW

Frimmersdorf,300 MW

Niederaussem,300 MW

Niederaussem (BoA 1),1000 MW

Neurath (BoA 2 and3), 1100 MWNeurath,

600 MW

Netefficiency

50%

40%

30%

20%

1960 1980 2000 2009

Efficiency improvements Original schedule for Neurath F and G

NEURATH

Activities 2002 2003 2004 2005 2006 2007 2008 2009 2010

Design studies

Awarding of main contracts

Preparation of request for approval

Detail engineering

Emissions approval procedure 06/20/2005

Levelling & preparatory works

Start of construction 01/01/2006

Construction and commissioning unit F

Civil works Jan 2010

Erection of 1st boiler column 07/01/2007

Start of turbine installation 04/27/2008 First ignition 04/05/2009

First power generation 07/26/2009

Trial run

Construction and comissioning unit GJuly 2010

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Immediately after the regional governmentapproval RWE Power started site preparation fortheBoA 2 and3 unitsat Neurathandin September2005 took the final decision to proceed with ther2.2 billion project. The decision was taken byRWE on the assumption that emissions rights

prevailingin 2005-2008 for new and replacementplants would continue to apply after 2008 under

NAP (National Allocation Plan) 2.A crucial objective of the new units is a

reduction of CO2 emissions for RWEs lignitepower plant fleet as a whole, via increasedefficiency and the shutting down of old, lessefficient, units.

With an efficiency of more than 43% the BoAunits certainly meet this goal.

The replacement of the old 150 MW units byBoA 2 and 3 will lead to a reduction in CO 2emissions of about 6 million t/y relative to theemissionsthatwouldbeproducedbytheoldunitsin generatingan equivalentamount of electricity.

The site area occupied by the two new units atNeurath is just under 37 ha and less than 40% ofthis will be occupied by buildings. As anecological offset for the erection of the two new

power plant units, including rail links andoverhead lines, RWE is reforesting some 21 haof farmland in the areas of Neurath, Sinstedenand Vanikum. In addition special farmingmethods will be introduced to a further 10 ha ofland to encourage wildlife habitation.

Commercial operation of the new Neurathunits is envisaged for 2010. However work onthe unit F steam generator was suspended inOctober 2007 due to a seriousaccident. Work onunit G has continued, while preparations are

underway to restart work on the unit F steamgenerator shortly. While the original schedule(see p 23) envisaged that unit F would start up

before G, the order is now likely to be reversed.

PlantdescriptionThe high efficiency of the BoA 2 and 3 units at

Neurath can be ascribed to: the steam conditions(600/605C); the steam turbine technology; thenine-stage feedwater preheating system; themaximisation of waste heat recovery from the fluegas;andminimisationofauxiliarypowerneeds(egthrough use of turbine driven feedwater pumps).

The two new units are located to the east of theexisting Neurath units and will make use of

existing facilites where possible, some of whichmust in part be retrofitted or extended.

Forlignite supplies, a newcoalyardin theformof an underground slot-bottom bin is being built.The raw lignite will be delivered to the new binusing RWEs own northsouth railwayconnecting thepowerplantsite to theGarzweilerand Hambach opencast mines.

From there, the lignite will be transported by anew conveyor belt system to the day bins in the

boiler houses.The lignite mills pulverise the lignite and, to

lower its high moisture content (48 to 60%), dryit using hot flue gases taken from the furnace.

Next, together with heated air from the flue-gasairheater, thepulverised lignite is blown into thecombustion chamber of the steam generator.

The once through steam generators each have

a capacity of 2392 MWt (2800 MWt max) andare the largest lignite fired boilers in the world,with the highest steam mass flows, supercriticalsteam pressures and steam temperatures everreached for lignite the size (notably the height)coupled with the steam parameters creating

particular challenges.Combustion is subject to constant monitoring

and adjustment of the lignite and air feed, so thatit is optimised and NOx production minimised.The legally prescribed emission limit values for

NOx 200 mg/m3 of flue gas can be

comfortably met by these combustion measuresalone, without additional post combustionsystems, eg selective catalytic reduction.

The lignite combustion temperature is about

1200C. The hot flue gas that emerges duringcombustion flows through the steam generatorfrom bottom to top. In the process, it transfersheat to the outer walls, which consist of tubes,and to the tube banks suspended in the flue-gas

Site plan for

Neurath F&G

G

H

MJ

K

F

E

L

D

C

B

A

A Main switchgear andcontrol building

B Turbine hall

C Intermediate buildingD Boiler house

E Electrostatic precipitator

F Induced draft fanbuilding

G FGD building

H Switchgear building forFGD

J Cooling towerK Cooling water pump

house

L Coal conveyor bridge

M Coal bunker

Key contractors and themulti contractapproach

Siteas of5 March 2008. The picture shows thefour stair towers, twoper unit and, in thecentre

of thepicture,boiler structural steel forunit F

(right),where theOctober accident occurred,

and for unitG (left)

Energy capitalThe Grevenbroich region, where the Neurathplant is located, has traditionally played animportant role in energy supply: it was close tohere that thefirst lignitedepositin thenorthernmining area was discovered. That was back in

1858, andfor decades,the lignite was mined inopencast operations and upgraded in twoneighbouring briquette factories. Despite thismining tradition, the Neurath power plant siteis relatively young compared with the otherRhenish powerplantlocations: thefirst unit only went on streamin 1972 andby 1976, a total of three300 MW units and two 600 MW units had been commissioned.

Like all other large lignite-based power plants, the Neurath power station, which uses lignite fromthe Garzweiler and Hambach opencast mines, operates in baseload mode.

RWEnow minessome 100 million tons oflignite everyyearin theRhenishlignite-miningarea, mostof which is used to generate electricity. Lignite needs no subsidies andrepresents an economicassetfor the entire region.

Theexisting

Neurathplant

RWE

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flow. Heated feedwaterflows through these tubesystems and is evaporated and superheated.

After thetopmost bank of heating surfaces, theflue gas is redirected to the downward open-passduct and distributed across the two flue-gas airheaters to preheat the combustion air. Afterflowing through these heat exchangers, the fluegas cooled from about 350C to 160C isconducted in two parallel lines to flue gas

cleaning systems. The latter consist of dustextraction, by electrostatic precipitation,followed by flue gas desulphurisation (FGD).

A further portion of the remainingflue-gas heatis removed from the flue gas before it is fed intothedesulphurisation plantvia fluegas coolers andtransferred via a heat-transfer cycle to a part-flowofthecondensateinthefeedwaterheatingsection.This lowers the flue-gas temperature to 125C

before it enters the flue gas desulphurisationsystem, which employs polypropylene andconcrete for the scrubber wall materials.

The main steam produced by the steamgenerator has a pressure of 272 bar and atemperature of 600C and is initially expandedto 58.7bar in theturbines high-pressure section,where the temperature falls to 356C. This steamis conducted back to the steam generator andsuperheated again (reheated) to 605C. In the

Schematicof thenewNeurath units,F andG

The Neurath F &G

boilers areof the

wellproven single

pass type. The

large dimensionsallowlignitefrom

the localmining

area tobe used

Technicaldata

Firing thermal capacity 2392 MW (max. 2800)

Lignite feed 820 t/h (max. 1300)

Main steam 272 bar / 600C

Hot reheat steam 55 bar / 605C

Total dimensions 170 m x 100 m x 100 m

Dimensi ons of boi ler 14 2m x 26 m x 26 m

Heating surfaces 146 000 m2 (~15 ha)

Thefour casingsteamturbine

(STF100 type)

The two-polegenerator,the largest suchmachine

yetbuilt

Neurath innovation: polypropyleneandconcrete

areused forthe flue gasscrubber internalwalls

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intermediate- and low-pressure sections thesteam expands to the pressure of 48 mbar

prevailing in the condenser, where it isprecipitated as water.

The cooling water is re-cooled in the coolingtowerbyfallingasrainincontinuouscontactwithcooling air. The cooling air required for this inthe energy-efficient natural-draught towernecessitates the tower height of around 170 m.

The cooling water that evaporates during re-

cooling and the cooling water that must bedischarged to avoid excess concentrations of salthasto be replaced on a continuousbasis. Forthis,use is made primarily of makeup water from theFrimmersdorf powerplant, whichis treated there

before it is deployed in Neurath. As an

alternative, the new units can also be suppliedwith treated water from Niederaussem.

The steam turbines, each rated at 1100 MWe,are of the Alstom STF100 type. They employfully flow optimised blading.

At Neuratha compactfour casing configurationis employed: HP, IP and two LP (whereas at

Niederaussem there is a three-casing LP) .The two-casing four-flow low pressure turbine

stage is made possible through the use of

titanium 1.408 m last stage blades the longestlast stage blades currently offered on the worldmarket, providing an exhaust cross section of13.2 m2. The compactness of the steam turbinecontributes to reduced construction costs.

TheelectricalgeneratorsareoftheGigatoptype

(with hydrogen cooled rotor and water cooledstator) and, at 1333 MVA, these will be amongthehighest ratedtwo-polemachines in theworld.

The generator terminal voltage is 27 kV. Thevoltageissteppedupto380kVforgridconnection.

Environmental impactsAswellas reduced CO2 emissions,the newunitswill also achieve low specific SO2, NOx and dustemission levels.

They will certainly be comfortably below thestatutory limits, as specified in the Germanordinance on largecombustion plants: SO2 200mg/m3 and a minimum sulphur removal rate of85%; NOx 200 mg/m

3; CO 200 mg/m3; andparticulates 20 mg/m3.

The combustion

processThewatersteam cycle

Fluegas cleaning schematic Cooling tower andGRP

clean-flue-gasduct

Insidethe unit F cooling

tower (March 2008)

Steam generator Steam generator

Reheat steam pipes

Main steam pipe

Feedwatertank

TurbineGenerator

Cooling water

Condenser

Feedpumpdriveturbine

Feedpumps

LPheater

HPheater

from theheat-transfer

system

to the heat-transfersystem Main

condensate

pumps

Condensatepolishing plant

Condensatebooster pumps

Makeup condensate

Open pass

Air heaterto flue-gascleaning

FD fan

Long-distanceash conveyor

to the dump in theopencast mine

Reheat steam pipesMain steam pipe

Lignite bin

Feedwater

Ignitionfuel

Lignite mills

Ash removal

Wet-slagextractor

Cooling waterDry-ash fromthe ESP

Dry-ash bin Wet-ash bin

Ash wetting

Ash train to

dump

Flue-gas dischargevia cooling tower

Flue-gasdesulphurisation

(FGD) plant

FGD makeupwater

Flue-gascooler Electrostatic precipitator

Flue gas

ID fan

Dry-ashbin

Ashwetting

Ash train tothe dump

Wagonunloading

Limestonesilo

Limestone slurry

Long-distance ash conveyor

to the dump in opencast mine

Gypsum utilisation

Gypsumstore

Circulationwater tank

Belt filter

Gypsum dewatering

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As already touched optimised combustion inthe furnace limits NO

x

formation, as well as CO.The electrostaticprecipitators separate out more

than 99.8% of the dust carried by the flue gas.While over 90% of the sulphur dioxide from

the flue gas is removed by the FGD plant andturned into gypsum.

For flue gas desulphurisation, a wet limestoneprocess is employed.

For process-related reasons, the main wastesproduced by the power plant will be dry and wetash as well as gypsum.

Some of the gypsum will be sold to theconstruction material industry. But, due to theinevitable variations in gypsum quality arisingfrom the strongly fluctuating ash composition,

and due to the likelihood of insufficient demandfrom thebuilding sector, some of thegypsum will

be used together with lignite ash for backfillingthemines fromwhichthe lignite willbe extracted.

For the other process-related byproducts, it isplanned to re-use them in the power plant.

The calciferous sludge from water treatment,for example, can be used to reduce pulverisedlimestone needs in the flue gas desulphurisation

process.Water management is another key

environmental consideration. The waterneeds ofa power plant unit are determined mainly by theevaporation losses when the heat is dischargedin the cooling tower.

In addition, to avoid any critical salt

concentrations, some of the cooling water mustbe continually removed from the cooling cycleand replaced.

Some of the removed cooling water directlycovers the needs of other water consumers (eg,the FGD), while excess amounts are directlydischarged into the outfall ditch.

For service water, a purification plant will beavailable and the treated water will be releasedintothe outfall ditch. Anysurfacewateroccurringwill be initially collected in a rainwater settling

basin and then released into the outfall ditch.The minimising of noise has also been a key

objective, requiring all mechanical equipment inthe new units to be installed in enclosed rooms.

Within the units sound-proofing will be usedas required to ensurethat levelsin thework areasarewell belowthe permissiblevalues.Low-noisemachinery is being used where possible, butwhere it is not possible additional sound-

proofing enclosures or structural partitions arebeing provided.

For the air inlets and outlets of the buildings,silencers are employed. To limit the noiseemissions from the cooling towers, which are

The cooling cycle

Technicaldata

Bunker volume 50 000 t

Storage capacity 30 h (design)

O ve ra ll di me ns io ns 3 10 m x 3 3m x 2 3 m

Excavation 605 000 m3

Concrete volume 60 000 m3

Crosssection through

underground coalbunker

Theexcavationfor theunderground bunker

(Sept 2006),up to43 mdeep inparts

Aerialviewof coal bunker, Feb2008

Summaryof key data for Neurath F and GLocation Grevenbroich, Neurath

(near Cologne,Germany)

Owner/operator RWE Power AG

Fuel Lignite (domestic)

Cool ing system Cool ing tower withnatural draught

Installed capacity (MWe) 1100 gross, 1050 net

Net efficiency (%) Grea ter than 43

Flue-gas waste heatutil isa tion (degrees) 350/160/125

SteamgeneratorType Once-through, tower

Steam flow (t/h) 2 870 (296 0 max)

Steam pressure (bar) 272 (280.4 max)

Steam temperature (C) 600

Furnace capacity (MWt) 2392 (2800 max)

Raw lignite input(guarantee lignite)(t/h) 820 (1326 max)

SteamturbineType STF100

Number of modules (casings) 4

Steam pressure (bar) 259

Steam temperature inlet/reheat (C) 595/604

Speed (rpm) 3000

GeneratorType GIGATOP

Rating (MVA) 1333

Power factor 0.825

Frequency (Hz) 50

Terminal voltage (kV) 27

Excitation system Static excitation system

Cooling system Hydrogen plus wa ter

CondensingplantCirculating watertemperature (C) 18.2

Condenser pressure (mb ar) 48

Tube material Stainless steel

Feedwater heating plant

Number of feedwaterpreheating stages 9

Number of feedwater heaters 8

Number of feedwaterdeaerating tanks 1

Feedwater inlettemperature (C) 292

MainpumpsCondensate extractionpumps (%) 3 x 50

Feedwater pump 1 x 100 % main turbodriven feedwater

pump plus2 x 40% start-up

motor drivenfeedwater pumps

Circulating water pumps (%) 2 x 50

Polishing plant Yes

Main transformersRated output (MVA) 2 x 1100 (per unit)

Prima ry/secondary (kV) 420/27

Unit transformers

Ra ted outp ut (MVA) 2 x 100/60/ 60(per unit)

Primary/secondary(kV) 27/10.5/10.5

Standby transformerRated output (MVA) 90/45/45

Primary/secondary (kV) 110/10.5/10.5

Low-pressuresection turbine

Steam

Flue-gasinlet

Cooling water Condenser

Water /condensate

Ambientair

Fill packaging

Distribution pipe withspraying system

Mist eliminator

Ambientair

Sound-controlwall

coal trains

hoppersurfaces

conveyors

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mainly produced by the water falling into thebottom section, acoustic barriers are beingerected outside them.

Assessments indicate that statutory noiseemission levels in the vicinity of the power plantwill be met comfortably.

Even though it is envisaged that all statutoryenvironmental requirements for the power plantwill be met by a good margin when F and G startup, nevertheless the new units haveenvironmental implications for their immediatesurroundings. Therefore experts at TUVAnlagentechnik GmbH have assessed theenvironmental compatibility of the F/G project.Backed by individual expert opinions, the impacton air, climate, soil, water, flora and fauna and,ultimately, humans, was assessed, as well as the

potential impact on the landscape.Comprehensive measurements made between

December 2002and June2003 recorded thethenexisting levels of nitrogen dioxide and airborne

particles (PM10) and included an evaluation ofthe heavy metals in the airborne particles anddustfall at Rommerskirchen-Nettesheim. In the

period December 2003 to June 2004measurements of prior contamination bydioxins/furans were carried out. Further priorcontamination data were obtained frommeasuring stations operated by the environmentoffice of the state of North Rhine-Westphalia.

Using the calculation procedures prescribed inGermanys TA Luft and supporting wind-tunneltrials, the additional air pollution from the F andG units was calculated and the total pollution to

be expected estimated . The results are shown in

the table below.It canbe seen that theadditional pollutionfrom

each individual air pollutant is no more than 3%of the air-quality values of TA Luft and thatoverall pollution levels arebelow the permissibleair-quality values.

The data on existing, additional and total aircontamination apply to the most unfavourablesituation in each case in theregion beingassessedand the additional contamination due to the newunits assumes they are emitting at the maximumadmissible levels. Under normal operatingconditionsactualemissionswouldbe muchlower.

The future for ligniteLooking beyond Neurath F and G RWE Power isworking on the next generation of lignite-fired

power plants. These are expected to offer about afourpercentage point increase in efficiencythanksto the use of dried rather than raw lignite, as usedin todays plants, including Neurath F and G.

RWE Power is developing a drying technologycalled WTA fluidised bed drying with internalwasteheatutilizationforthispurpose(seeModern

Power Systems, December 2007, pp 17-21A demonstration facility has been built next to

the Niederaussem BoA unit and commissioninghas just begun. The facility will trial thetechnology for the first time in conjunction witha large-scale power plant, with the aim ofdemonstrating that the WTA system incontinuous operation is both technically andeconomically viable.

WTA is a proprietary development of RWEPower and since 1993 it has been undergoingtrials and steady development at Frechen and

Niederaussem.

WTA technology is also proposed as part of amajor retrofit planned for the Hazelwood power

plant in Australia (see Modern Power Systems,December 2007, pp 22-29).

It is expected that German electricity demandwill grow only modestly in the coming decades.Over the past 10 years, consumption hasincreased by about 1% per annum.

However, while demand will hardly change,there are signs of major shifts in Germanys

energy mix. Above all there is the projectedphase-out of nuclear power the share of whichin powergeneration hitherto hasbeensome 22%.This may be questionable in terms of climate

policy and the impact on the energy sector, butit has been agreed between the federalgovernmentand the energy sector and potentiallycreates a huge generation gap that must be

bridged. If the phase-out happens the nuclearcontribution to annual electricity supply

presently around 140-170 billion kWh per year will dwindle to nothing by 2030.

The German domestic renewable energysources hydro, wind, biomass, landfill gas,solar, geothermal and waste-to-energy are at

present making an 11% contribution towardspower generation.

Thefederal government is pursuing thegoal ofincreasing the share of renewables in electricitygeneration to at least 20% by the year 2020 and

by the middle of the century as much as one halfof all energy is to come from renewables.

Natural gas, too, is likely to enjoy an increasingshare of the power generation market. It alreadyaccounts for around 12% of the total.

The outlook for hard coal is mixed: a declinein the use of domestically mined fuel and anincrease in the use of imported coal.

But meeting power needs from natural gas,imported hard coal, and increased electricityimports creates fewer domestic jobs and less

value added than electricity from indigenousenergysources such as lignite. It is estimatedthateconomically mineable lignite deposits inGermany are sufficient to last for generations tocome. Also, the lignite can be extracted undercompetitive conditions and the industry can get

by without subsidy.Currentlylignite fired powerplants account for

about a quarter of Germanys electricityproduction, with Rhenish lignite providing about13% of the total electricity.

Analyses, eg by thePrognosresearchinstitute,have suggested that lignite may even gain inimportance as an electricity source in the longterm future. But this need not be at the expenseof the environment or theclimate thanks to more

efficient power plants, as exemplified byNeurath F and G. MPS

The future: WTA lignite predrying

Expected effect of Neurath F and G on air qualityWhat percentage of theallowed

air-quality v alue w ill b e reached a fter By w hat p ercentage d oes a ir p ollution

units F and G enter o peration? increase a fter u nits F and G enter o peration?

Total air pollution after units

Admissible F and G are commissioned Max. additional

air-quality value (sum of prior and contamination from

under TA Luft added contamination) Prior contamination operating units F and G

Percentage of Percentage of Percentage of

admissible air- admissible air- admissible air-

mg per m3 air g per m3 air quality v alue g p er m3air quality value g per m3 air quality value

Sulphur dioxide 50.0 7.6 15.2% 7.0 14.0% 0.6 1.2%Nitrogen dioxide (NOx) 40.0 32.7 81.8% 32.5 81.3% 0.2 0.5%

Airborne particles 40.0 30.1 75.3% 30.0 75.0% 0.1 0.3%

g per m2 and day g per m2 and day g per m2 and day g per m2 and day

Dustfall 0.35 0.114 32.6 % g 0.114 32.6% 0.00002 0.006%

BoA concept BoA concept with predried lignite

Integratedmilldrying

Boiler

Flue gas

+ vapour1000C hotflue gas

Raw lignite

Dry lignite+ flue gas+ vapour

Energetic disadvantages:

drying at very high exergy level

no use made of vapour energy

Energetic improvement:

drying at low exergy level (low-pressure vapour)

use made of vapour energy

Predrying(WTA)

Boiler

Flue gas

Fluidized-bed drier

Dry ligniteCondensate

Rawlignite

Heating steamfrom turbine bleed

Vapour for boilerfeedwater heating

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