renovation and modernization of lignite fired … and modernization of lignite fired power plant ......

1 | 4th EU - South Africa Coal & Clean Coal Working Group Meeting | 2012-11-05

Renovation and Modernization of Lignite fired Power Plant Boxberg

Guenter HeimannVattenfall Europe Generation AG, BU Lignite

Confidentiality - None (C1)

4th EU South Africa Coal and Clean Coal Working Group Meeting

Johannesburg, 5-6 Nov 2012



Table of contents

Results3

The USC Units Box Q + R3

Outlook3

Renovation & Modernization Program of Boxberg Power plant

2

Vattenfall in brief1


Vattenfall in brief



Vattenfall: a leading European energy company

• Vattenfall is one of Europe's largest generators of electricity and largest producer of heat

• Operations were conducted in Sweden, the Netherlands, Germany, Finland, Denmark, Poland,Belgium, France and the UK with up to 7.8 millions of electricity costumers

• Electricity: generation, transmission and distribution• Heat: production, transmission and distribution• Gas: transmission und distribution • Energy trading and lignite mining• Consulting and contracting activities in the energy sectors• approximately 38,000 employees• The parent company, Vattenfall AB, is 100 %

owned by the Swedish state



Vattenfall structure

Organisation since 1st January 2011

Board of Directors

Staff Functions

BU R&D Projects

BU Engineering BU Nuclear

BU Lignite BU Asset Optimisation Continental

BU Asset Optimisation Nordic

BU Trading

BU Operations

BU Hydro

BU Thermal andHeat

BU Thermal Projects

Chief Financial Officer

BD ProductionBD Asset

Optimisation and Trading

BU Customer Service

BD Distributionand Sales

BU Sales B2C

BU Sales B2B

BD Asset Development

BU OnshoreWind Projects

BD Renewables

BU OffshoreWind Projects

BU Generation Wind

BU Nuclear & Hydro Power Projects

BU Project Governance& Improvement

BU Heat

BU Distribution

BU EnergyRelated Services

BU Biomass

Chief Executive Officer



Vattenfall‘s electricity generation 2011

34,5

42,5

85

3,4

1,3

0

20

40

60

80

100

120

140

160

180

2011

Elec

trici

ty P

rodu

ctio

n [T

Wh]

Biomass / WasteWindFossilNuclearHydro

166.7 TWh

Source: Year End Report 2011

89.7 %

52,913 TWh

56.9 million t

59,367 kt

Key figures 2011

Availability Lignite:

Power generation Lignite:

CO2 absolute:

Coal quantity:



Power plants of BU Lignite Mining & Generation

power plant Jänschwaldecapacity: 6 * 500 MWinitial start-up: 1981-1989efficiency: 36 %

power plant Boxberg blocks N/Pcapacity: 2 * 500 MWinitial start-up: 1979/1980efficiency: 36 %

power plant Schwarze Pumpecapacity: 2 * 800 MWinitial start-up: 1997/1998efficiency: 41 %

power plant Lippendorfcapacity: 2 * 920 MW (50 % share) initial start-up: 1999/2000efficiency: 43 %

power plant Boxberg block Qcapacity: 900 MWinitial start-up: 2000efficiency: 43 %

500 MW units

800/900 MW units

+ 675 MWBoxberg unit R

3,420 MW

4,000 MW

7,420 MW8,095 MW

gross capacity

800/900 units

500 MW units

Lignite power plants

new build



Further Coal PP of Vattenfall Group

Hard Coal PPMoorburg (GE)2 x 820 MWelunder Construction

Hard Coal PPBuggenum (NL)240 MWel

Hard Coal PPHemweg (NL)630 MWel

Hard Coal PPFynsvaerket (DK)409 MWel

Hard Coal PPAmagervaerket (DK)319 MWel

Hard Coal PPNordjyllandsvaerket (DK)660 MWel

Hard Coal PPReuter West (GE)560 MWel

Hard Coal PPTiefstack (GE)320 MWel

Installed Capacity based on Hard Coal > 5.000 MW



Overview on Vattenfall’s lignite assets

3

4

3

2

2

Flexibility[%-PN/min]

800/900 MW

class(supercritical boilers)

500 MW

class

2000

2000

1997 / 98

1981-88

1978 / 79

commissioning

547°C260 bar41.2 %2 x 800 MWSchwarze

Pumpe

554°C267 bar42.8 %933 MWLippendorf

unit R

545°C266.4 bar42.4 %907 MWBoxberg unit Q

535°C163 bar35.5 %6 x 500 MWJänschwalde

535°C163 bar35.0 %2 x 500 MWBoxberg

units N/P

Life steam parameter

Net efficiency

Gross capacityPower plant



0%10%20%30%40%50%60%70%80%90%

100%

unplanned downtime 2,8 3 4,4 5,6 2,9 3,5

planned downtime 8,5 3,6 8,4 8,8 10,3 6,9

availability for work 88,7 93,4 87,2 85,6 86,7 89,5

2006 2007 2008 2009 2010 2011

Development of availability of lignite assets


Renovation & Modernization of Boxberg Power Plant



2575 MW

unit R 675 MWas of 2012

Start-up modules I / II / III / IV



Aerial view Boxberg site

Old 210 MW unitsdecommissioned

Unit N+P2 x 500 MWel

Unit Q900 MWel

Unit R675 MWel



Boxberg N + P – Technical Key Parameter

N: 240,000P: 237,000Operating hours

2 x 500 MWGross Output el

540 °CIntermediate steam temperature

125 MJ/s

35 %

530 °C

163 bar

2x815 t/h per unit

8.7 – 9.1 MJ/kg

560 t/h per unit

District heating

Net efficiency

Live steam temperature

Live steam pressure

Live steam quantity

Caloric value lignite

Raw coal output



Power Plant Boxberg – Technical Parameter

>1,400 100,000N: 240,000P: 237,000Operating hours

675 MW900 MW2 x 500 MWGross Output el

610 °C578 °C540 °CIntermediate steam temperature

Unit RUnit QUnit N and P

150 MJ/s

42 %

541 °C

258 bar

2 422 t/h

8.7 – 9.1 MJ/kg

890 t/h

125 MJ/s

35 %

530 °C

163 bar

2x815 t/h per unit

8.7 – 9.1 MJ/kg

560 t/h per unit

-District heating

43.7 %Net efficiency

600 °CLive steam temperature

285 barLive steam pressure

1710 t/hLive steam quantity

8.0 – 9.2 MJ/kgCaloric value lignite

612 t/hRaw coal output



500 MW Renovation & Modernization Program

IPhase

1991 - 1996

IIPhase

2002 - 2006

IIIPhase

2006 - 2014

„B500“



Modernization Phase I (1991-1996) 500 MW Units

Respective actions:- Modernization of the steam generator- Retrofit of the low pressure turbines- Installation of flue gas desulphurization plants (FGD)- Modernization of the electro filter- Change of the control system

I



Modernization of the steam boiler

Objective: compliance of all limit values and increase of the efficiency

- Reduction of NOx emission1. Conversion of the burner as low-NOx-burner2. Retrofit of over-fire-air-nozzles for a better

CO-burnout3. Reduction of the combustion air surplus

- Increase of the efficiency1. Increase of the controlled air content from 55 %

to > 85 %2. Decline of the exhaust temperature3. Reduction of the unburnt in slag and fly ash

Results:

- Δηboiler ≈ + 4.2 – 5.8 % pointsΔηunit, net ≈ + 1.5 – 2.2 % points

I



boiler

e-filter

coal

ash

>5000 mgSO2/Nm3

SO2 air

Flow chart

GS 1,4 %

condensator

cooling water-pump

New construction of flue gas desulphurization plant

absorber

water H2O

air O2

CaSO4

gypsyum

Flue gas SO2

Clean gas

cleaned fluegas /

limestone CaCO3

Flue

gas

with

> 50

00 m

g SO

2/ N

m3

water steamf

SO2 ≤

5%

max

. 400

mg/

Nm

3

Objective: Capture of SO2 of the flue gasconstruction of the FGD each boiler with flue gas dissipation in den cooling towercombining flue gas duct of e-filter over FGD to the cooling towerrenovation of the cooling tower with optimization of the installations

Result:- Unit auxiliary power requirements: + 2 % pointsΔηunit, net ≈ - 0.7 % points

I



Retrofit of LP Turbine

Target: Increase in EfficiencyMeasures:

Replacement of LP rotor and inner casing to achieve

- Flow improvement- performance increase- Elimination of Erosion

Results: - ΔηND-Turbine up to + 7 %-PunkteΔηBlock, netto + 1,5 - 1,9 %-Punkte

I



Modernization of ESP

Target: reduction of dust emissionIncrease of precipitation by

- replacing & optimizing the installed equipment- Optimizing the performance of electrodes- Reducing pressure loss

Avoiding operation below acid dew point by- Reducing ration of leak air- Improving insulation

I

Pre

Cle

anin

g Zo

ne

Flue GasInlet

Dry AshM

iddl

eC

lean

ing

Zone

Seco

ndar

yC

lean

ing

Zone

Flue Gasoutlet



Replacement of Control System

Legal and technical Requirements:-NOx-low Operation of the Steam boiler-Optimization E-Filter Control-Integration FGD into I&C systems-Grid control

Due to the existing I&C Ursarmar 4000 was obsolete as well as the unavailability of spare parts the exchange to processor-based I&C system was required!

Results:-Conformity with environmental and economic requirements

-Higher level of automation and simplified operation

-Common control room for two units with one operator for each unit

I



Modernization phase II (2002-2006) 500MW units

Retrofit to reach incineration of secondary fuels

Modernization of the control system

Retrofit of the HD turbines

II



Example: Retrofit HP-turbines 500MW Unit N+P

Before

- Fixed pressure operation- Equal pressure turbine blades (8 stages)- Central drilling at rotor- High maintenance expense – opening once in 4

years necessary- Efficiency: ηHP-turbine = 76 – 79 %

After

- Still fixed pressure operation- Optimised 3-D reaction pressure blades

(16 stages) pre-twisted with integral shroud bands

- Opening only once in 100,000 operating hours

- Efficiency: ηHP-turbine ≈ 89 %

∑ 3.5 mill. EUR each turbine

II



• Integration of the required measures into the revision cycle of 4/8 years during the period of time from 2008 to 2014

• Maintenance of the known characteristics of the 500-MW-equipment

• Basis of the project are the maintenance projects planned in medium-term planning

• Realisation of provable economic measures only

• Project period from 2008 to 2014

Project goals

• Maintenance of the technical safety and an availability of at least 90 %• Further operation of the eight 500-MW-units on the site of Jänschwalde by 2029

and of Boxberg by 2031

Modernization Phase 3 - B500 Retrofit Program

Fundamentals

Avoidance of additional downtime

Technical innovations result in improvements

III



B500 Program

Project Study

• Inspection/assessment of the 500-MW-units at the Jänschwalde and BoxbergPower Plants within the framework of a Study in the years 2005/ 2006

• This Study included the cost finding of the determined scope of the project

Requests to suppliers for information offers as far as the required measures in 01/2006 are concerned

Approval of the project

• In December 2006 the project was approved by Vattenfall Board based on econmical evaluations.

• This value scope corresponded to the cost estimate determined within the framework of the study.

Integration of the measures into the Revision Plan 2008-2014

III



B500 Measures at the 500MW units at Boxberg

• Replacement HZÜ (reheater) steam pipe at units N+P

• Replacement/Recoiling unit transformer at units N+P

• Replacement SPAT (feed water power turbine)

(4 TSP (turbo feed pump)- power turbines)

• Replacement of automation system until 2014

• Replacement of electrical feed pumps

• Coil end stabilisation generator at units N+P

• Waste water treatment for service water

• Raw water supply, new section

• Auxiliary cooling and service water pipes

• Replacement of 10-kV-engines

III



Planned Modification 2013/14 - IP Retrofit 500 MW

Scope of supply:• New IP Rotor with 3D Reaction Type

Blading• New IP Inner Casing and Blade

Carriers with 3D Reaction Type Blading• Gland Casing seals and Coupling Parts• Installation and Alignment into the

existing Outer Casing

expected results:• Power increase of > 6,3 MW (green)• Reduce of Heat Consumption

of > 90 kJ/kWh• Save more than 45.000 t/CO2 per Year• Reducing Overhaul Costs• Improving Reliability and Availability

for the remaining Life Time

III



Renovation & Modernization Program 500 MW Units

Results

I



Overview of Main Measures of Modernization Program from 1990-2014

• Replacement of the heat recovery adjunct except ECO and HD1 (high pressure) and improvement of the control

• Conversion of the firing system • Conversion of the ignition oil supply

towards light fuel oil• REA retrofitting

• Partial replacement of E-technology

• Rewiring of 650 km cable

• Modernisation of the cooling tower – installation of high perfomance frigistors

• Installation of Taprogge facility• Replacement of sealed bearings

• Complete replacement of control and communication technology

• Introduction of workstations• Increased levels of automatisation• New 1000 MW – unit control room

• HD- Retrofit• Replacement of MD

(medium pressure)-rotor

• Replacement of automation system

• Raw water supply • Waste water treatment

• Auxiliary cooling water and service water

Legend : black Improvements during the 1990ies purple extension of operation B500

ESPTSP



Results of Retrofits of 500 MW Turbines

95

70

75

80

85

90

HD MD ND

Efficiency [%]

Before Modernization After ModernizationBFPT

- 680 kJ/kWhElectrical Power

+ 52 MW

Heat Consumption

G

535MW

Δ = + 3,4Δ = + 11Δ = + 10 / 13

Δ = + 7,6

Main Steam Turbine Set BFPT’s



Results of the modernization till 2006

φφØ Operating performanceComparison 1989 and 2005

Net efficiencyComparison 1989 and 2005

II



Results of the modernization till 2006

boiler e-filterFlue gas

desulphurization plant

Dust

II


The USC UnitsBoxQ and R



Boxberg Q – Technical Key Parameter

100,000Operating hours

900 MWGross Output el

578 °CIntermediate steam temperature

150 MJ/s

42 %

541 °C

258 bar

2 422 t/h

8.7 – 9.1 MJ/kg

890 t/h

District heating

Net efficiency

Live steam temperature

Live steam pressure

Live steam quantity

Caloric value lignite

Raw coal output



L&C Steinmüller / Babcock Lentjes

Type: forced flow

580 °CIntermediate steam temperature =

8Number of mills =

545 °CLive steam temperature =

58 barIntermediate steam temperature =

266 barLive steam pressure =

581 kg/sIntermediate steamquantity =

673 kg/sLive steam - quantity =

Cleaning plants

Water lance blowers 16 piecesRetractable soot blowers 84 piecesLance blowers 42 pieces

Unit Q – Steam Boiler 2,422 t/h



9StagesFeedwater Preheating

290°CFeedwater - Boiler Inlet Temperature

46.1%Unit Efficiency brutto

640MWPower Output net

35MWAux Power

closed loop, cooling tower-Cooling system

4.5mill t/aFuel Consumption

33mbarLP- Exhaust Pressure

Operation Mode - Base LoadFuel - LignitePower Output brutto MW 675

Unit Efficiency net % 43.7

Live Steam °C / bar 600 / 286Intermediate Steam °C / bar 610 / 50

spec CO2-Emission g/kWhnet 924

Boxberg R – Technical Key Parameter


4. Outlook



Coal had a share of 43.5 % ofGermanys electricity production in 2011

Electricity generation in Germany 2011

Overall electricity production (gross): 614.5 TWhOverall installed capacity: 167,820 MW

Source: BDEW 03/2012

Share of energy sources in %

3.16.1

3.2

5.2

7.6

13.7

17.6

18.6

24.9lignitehard coalnucleargaswindbiomasshydroPVother



Growth of wind and solar capacity in Germany

Source: Prognos, base scenario 2010A, September 2011

27,2 2946

6376 79

18,46,1

6565

63

52

2516,51,80,1

0

20

40

60

80

100

120

140

160

2000 2005 2010 2011 2020 2030 2040 2050

Inst

alle

d C

apac

ity [G

W]

Wind (total) Solar

Prognosis

The increasing share of discontinuous generated electricity fromrenewable plants with feed-in priority requires a significantly higher

controllability of conventional power plants.



Development perspective

• challenges today and in the futureSecurity of supply

Economic efficiencyEnvironmental compatibility

Flexibility

• this means the meaningful use of all different types of production

regenerative ↔ coal ↔ gas

• massive expansion of the electricity grid and development of the storage techno-logy

(Lignite) power plants are an indispensable part of the German

electricity supply in the technical and economic view


Thank you for your attention!

renovation and modernization of lignite fired … and modernization of lignite fired power plant ......

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