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3 Nos. 660 MW - Coal Fired Supercritical: Conference - ENERGEX 2008 Date: 26-09-2008

The document summarizes the conversion of an existing oil-fired power plant in Italy to run on coal. Key points: - ANSALDO CALDAIE was awarded the contract in 2004 to replace the 4 existing 660 MW oil-fired units with 3 new 660 MW supercritical coal-fired boilers. - The conversion was driven by higher fuel costs of oil and more stringent emission regulations. The new boilers help meet EU emission limits for SO2, NOx and dust. - The boiler design includes features like a divided back pass for temperature control and spiral-wound waterwall tubes for even heat absorption. Auxiliary systems include low-NOx burners and SCR for emissions control

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Sarah Frazier
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106 views19 pages

3 Nos. 660 MW - Coal Fired Supercritical: Conference - ENERGEX 2008 Date: 26-09-2008

The document summarizes the conversion of an existing oil-fired power plant in Italy to run on coal. Key points: - ANSALDO CALDAIE was awarded the contract in 2004 to replace the 4 existing 660 MW oil-fired units with 3 new 660 MW supercritical coal-fired boilers. - The conversion was driven by higher fuel costs of oil and more stringent emission regulations. The new boilers help meet EU emission limits for SO2, NOx and dust. - The boiler design includes features like a divided back pass for temperature control and spiral-wound waterwall tubes for even heat absorption. Auxiliary systems include low-NOx burners and SCR for emissions control

Uploaded by

Sarah Frazier
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPS, PDF, TXT or read online on Scribd
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3 Nos.

660 MW coal fired Supercritical

Conference ENERGEX 2008


Date : 26-09-2008
By
M.V. Radhakrishnan
ANSALDOCALDAIE Boilers India Private Limited,

INTRODUCTION

ANSALDO CALDAIE
with consortium of Hitachi was
awarded the boiler contract
on 1 Dec 2004
CUSTOMER
CONTRACT

:
:

ENEL POWER
LSTK

Torrevaldaliga
North- Power
Station

OVERVIEW OF HISTORY

Total gross electric power (Mwe) : 2,640

Net efficiency
39%
SH outlet temp.
540C
RH outlet temp. 540C
SH outlet pressure
253 bar

Fuel oil with 0.23% sulphur content

Flue gas treatment


FGD
NO
SCR
YES
Filters electrostatic YES

Emission limits
SO2
mg/Nm3 guaranteed (Monthly average)
NOx
mg/Nm3 guaranteed (Monthly average)
Dust
mg/Nm3 guaranteed (Monthly average)
Source : ENEL data

400
200
50

OVERVIEW OF HISTORY

4 X 660 MW oil fired supercritical units


Start-up between 1984 and 1986

DRIVING FACTORS FOR


CONVERSION
FUEL COST BEING HIGHER
LIFE OF PLANT EXAHUSTED
PRESENT STRINGENT EMISSION
NORMS
REDUCTION OF GENERATION COST

KEY CHALLANGES

MEETING EU NEW EMISSION NORMS


UTILIZING SOME OF EXISTING PLANT
HARDWARES
WIDE VARIETY OF COALS ##
SPACE CONSTRAINTS FOR STORAGE,ERECTION

## To maximize the usage of


geographical location of plant
near port

FEATURES OF NEW BOILER


Divided back pass with
biasing dampers for RH
outlet temp control

Spiral-wound waterwall tubes

Even heat absorption


uniform water temp
distribution at outlet;
Adequate mass velocity
adequate margins against
DNB occurrence;
Flow stability;
Moderate pressure drop.

Start up and low load system


Separators
Water collecting vessel
Recirculation pump
Lower start up heat loss
Ensures adequate cooling flow at
low load (below BENSON load)

FEATURES OF NEW BOILER


Boiler Parameters :
Unit type

: Super Critical

SHO flow

: 1918 t/h

SHO temp

: 604 deg c

SHO pr

: 252 bar

FW temp

: 313 deg c

RH in / out

: 370 / 612 deg c

RH flow

: 1576 t/h

RH pr.

: 58 bar

Furnace type

: Balanced draft

Water wall

: Spiral / Ribbed

Size

: 22.5 m x 14.2 m

SH / RH stages : 3 / 2
SH temp control : Spray attemp.
RH temp control: Gas biasing
Economiser

: Fin tubes

Fuel :
Design Fuel

: COAL (South African)

Characteristics : HHV 26.4MJ/kg, Ash 13.6 %, Moisture 7.4 %


Start-up fuel

: Natural Gas

Source of coal : Indonesia, Australia,South America,Poland, China

FEATURES OF NEW BOILER


Boiler Aux:
Mills
: 5+1 (with rotary classifier
Burners : Opposed wall - Low Nox
with OFA
Fans
: 2 FD(axial)
2 PA(Radial)
2 ID (existing)
AH
: 2 Nos. Tri-sector
Lungstrom type
SB
: Wall blowers
Retractable for conv. Pass.

SCR :
Outlet Nox
(6% O2)
Catalyst type

: < 85 mg/Nm^3
: Plate

(can accommodate Honey comb also)

Reactor
downflow

: Vertical

(Medium : Air / SH steam)

Start-up philosophy:
At start-up & below 25 % load, steam water mixture is separated in the
separator vessel & water flowing back to storage tank is re-circulated in
economiser & furnace tubes by re-circulation pump.

MAJOR CONTRACT
ACTIVITIES

Dismantling of existing oil fired boilers, SCR & precipitators

Installation of new boilers & relating auxiliaries , critical piping

Installation of new SCR systems

Installation of new FGD systems(By Owner)

Installation of sleeve filters (By Owner)

Installation of new ash removal systems(Fly ash by owner)

Installation of closed remote controlled coal bunkers

Construction of two docks

BOILER ISLAND SUPPLIES


BOILER PROPER (PR. PARTS AND START-UP SYSTEM)
STEEL STRUCTURES FOR BOILER, BUNKER BAY AND SCR

REGENERATIVE AIR HEATERS (trisector type)

FD FANS (axial type) and PA FANS (radial type)

COAL BUNKERS

COAL PULVERIZING AND FIRING SYSTEM

NATURAL GAS START-UP AND WARM-UP FIRING SYSTEM

SCR SYSTEM

BOTTOM ASH REMOVAL SYSTEM (DRY TYPE)

CRITICAL PIPING (from boiler headers to steel structures boundary)

PLANT PFD

PFD TREATMENT

A LOOK AT EU NORMS

Emission

Limits according to
Italian law
Torrenord oil fired
units

European regulation
for new plants
(In force since
1/1/2008)

Limits as per
authorization for
Torrenord coal fired
plant

SO2

400

200

100

200

200

100

50

30

15

mg/nm^3

Nox
mg/nm^3

Dust
mg/nm^3

BEFORE & AFTER CONVERSION

Gross power,MW
Cycle Efficiency
Fuel

Before
2640
39 %
FO

Emissions reduced by
Sulphur oxide (SO2)
Nitric oxide (Nox)
Dust

Source : Enel data

82%
61%
82%

After
1980
45 %
Coal

SCHEDULE
BOILER WTS.
PR. PARTS

7000 T

NON. PR. PARTS

12000 T

TOTAL BOILER

26000 T

CONTRACT SCHEDULE MILESTONES

UNIT #1 PAC*
UNIT #2 PAC
UNIT #3 PAC

* Provisional Acceptance Certificate

MONTHS
43 MONTHS
47 MONTHS
53 MONTHS

CONSTRAINTS ENCOUNTERED

RAW MATERIALS FOR PR. PARTS PARTICULARLY HIGH ALLOY STEELS T91, T92
MAIN STEEL STRUCTURAL COMPONENTS WITH HEAVY THICKNESS PLATES
COMPLEX AND COMPACT BOILER LAY-OUT DUE TO THE LIMITED SPACE
LIMITED MATERIAL STORAGE & PRE-ASSEMBLY AREAS
LIMITED SITE ROAD ACCESS
ERECTION CONSTRAINSTS DUE LACK OF ACCESS

PLANT TODAY

Thank You

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