EC-ASEAN COGEN Programme Phase III Proven, Clean & Efficient Biomass, Coal, Gas Cogeneration COCO Phase III COCO Phase III
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
LOCATION OF MAP TA PHUT
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
Map Ta Phut Industrial Estate
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
Harbour Site, May 1990
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
Harbour Site, May 1999
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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%
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
.
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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%
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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.
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
The units as of today
EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration
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