coco phase iii proven, clean efficient biomass, coal, gas cogeneration ...€¦ · proven, clean...

EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas CogenerationCOCO Phase IIICOCO Phase III

EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration

Leif Mortensen, Coal Expert

Cogeneration Week in Vietnam

6 – 9 April 2004Hanoi, Vietnam

Melia Hotel, Hanoi

2 x 230MW HYBRID Unitsat Map Ta Phut, Thailand

aCost-effective solution

Cogeneration


LOCATION OF MAP TA PHUT


Map Ta Phut Industrial Estate


Harbour Site, May 1990


Harbour Site, May 1999


Why the Cogeneration concept?

1. Reduced capital cost

2. Improved efficiency compared to separate units

3. The units can supply large quantities of HP Process steam


Reheater

CF boiler STG

STGHRSG

CTG

FW heaters

Generator

Generator

Generator

Gas- firedcombinedcycle

Conventionalcoal -firedpower plant

Individual units

CF boiler STG Generator

HRU

CTG Generator

Cogeneration concept

HRU Generator

Reduced capital cost

12%

ImprovedEfficiency

5.6%


Production cost of electricity

0,00

1,00

2,00

3,00

4,00

5,00

1 1,5 2 2,5 3

gas price/coal price

cent/kwh

Coal-fired Hybrid Gas -

Hybrid

Coal Gas


Schematic Cycle Diagram

.

.

HP steam

Coal

CFB

2 x HRU

LP eco HP eco

Reheater

2 x CTG

GasMP steam

STG

IP/LP

LP preheater

Make -up +return con-densate

G

G

HP

.


Map Ta Phut COCO Phase III -Basic Data

• Live Steam– Temperature 568 deg C– Pressure 183 bar – Flow 120.6 kg/s

• Reheat Steam– Temperature 530 deg C

• Condensing mode– Net electrical output 230 MW– Net efficiency 43%

• Extraction mode– Net electrical output 209 MW– MP steam production 100 t/h– Net overall efficiency 53%

EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas CogenerationOperational Experience

- commercial operation since March 2000

- total plant availability first year of operation: 93%

EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas CogenerationCoal part of units,

availability first year: 93%


Tests during final commissioningto prove the units basic capabilities and

flexibility

• Fully independent operation of CTG’s and CFB/STG • CFB stand alone• Hybrid units operating with CFB at 35%• Hybrid units operating with one HRU off-line• Hybrid units operating with maximum fuel input of

318 MJ/s• Demonstration of HP and MP production steam at

100% export– HP Export steam: 60 t/h– MP Export steam: 150 t/h


The units Performance Guarantees

• Total net electrical output 221.4 MW• Total net efficiency (at MCR) 41.8%• N0x emissions coal 49.5 mg/MJ• SO2 emissions coal 224 mg/MJ• Particle emissions coal 6.8 mg/MJ• N0x emissions gas 70 mg/MJ

• MCR: Main Steam 120.6kg/s, 182 bar, 568 deg C• Performance Tests Completed March 2000• All above values exceeded, except MCR conditions


Operational experience individual equipment

1. Too high reheat steam temperature drop when taking HRU in operation

Problem: - Turbine exposed to too high steam

temperature dropSolution:

- Change in operational procedure using a more gentle opening of steam admission and CTG exhaust gas admission through the HRU

Status:- Software solution implemented 1999


2. CFB Boiler main steam temperature too low

Problem:- Too much evaporative surface - Too little super heater surface

Solution:- Removal of evaporative wing walls- Adding Omega super heater surface

Status: - Wing wall remove June/July 1999- Omega super heater addition May/July

2001


3. ID-Fan impeller block 1 crack

Problem: - too high stress in impeller due to

unpredicted high dynamic stress Solution:

- measuring stress in block 2 impeller by installing strain gauges

- Analysing using finite element- Increasing ID Fan cone thickness

from 6 to 10mmStatus:

- Modification completed June 1999


4. Steam Turbine Block 1 erosion of IP Turbine

Problem:- Small Particle Impingement (SPI) to

IP Turbine diaphragms and bucketsSolution:

- Repair of stage 12 & 13 diaphragms- Replacement of stage 12 & 13 buckets

and spill stripsStatus:

- Repair of stage 12 & 13 diaphragms completed September 1999

- Replacement of stage 12 & 13 buckets to be completed May 2001


Conclusion

• The Map Ta Phut Cogeneration Concept has proven reliable, safe, operational and flexible

• The Plant has exceeded MW output and efficiency guarantees and fulfilled all emission guarantees

• The total Hybrid plant has shown availability of 93% during the first year of of commercial operation


Conclusion (cont.)

• The units and its main components have proven a good choice for a co-generation plant in the Map Ta Phut Industrial Estate

• Most operational problems encountered not related to hybrid concept, however solutions have been found to all the problems and rectification's implemented.


The units as of today


HP steam: 30 t/h MP steam: 70 t/h

Pstg: 130,0 MW

CFB Fuel: 302,6 MJ/s

CTG A fuel: 116,6 MJ/sPctg A: 35,0 MW

Tcond: 45 °C

CTG B fuel: 116,6 MJ/s

Pctg B: 35,0 MW

Ambient temperature: 32,2 °C

HP steam

HP Turbine IP and LP Turbine

Gasturbine CTG A Generator

Heat Reco-very Unit A

GeneratorGasturbine CTG B

CFB Boiler

Condensate

MP steam

CondenserFeed Water Tank

ST generator

Heat Reco-very Unit B

Unit Process


Thank You !

For more information, please visit COGEN 3 Website at:

http://www.cogen3.net

coco phase iii proven, clean efficient biomass, coal, gas cogeneration ...€¦ · proven, clean...

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