Presentation on CSP integration with conventional power plants Solar market in India 2013 7 th – 8 th May 2013, New Delhi Dr. J.T.Verghese – Managing Director.

Presentation on

CSP integration with conventional power plants

Solar market in India 2013 7th – 8th May 2013, New Delhi

Dr. J.T.Verghese – Managing Director Steag Energy Services India Pvt. Ltd.

• Steag and it’s services

• Hybridization concept examined for NTPC plant at Anta

• Hybridization studies for waste heat recovery boiler

• Hybridization studies at Steag power plants

• Hybridization concept for integrated solar biomass desalination plant

Topics for discussion

Steag’s Activities

Steag Germany - Key figures (as of Dec. 2011)

•External sales 3,066 € m

•Capital expenditure on fixed assets 1,283 € m

•Employees 5,800

Steag India Activities• Engineering Consultancy• O&M services – ~ 5000 MW• System Technology –

Simulators and Plant optimization systems

• Training and advisory services

Steag India – Solar activities• Several DPRs and feasibilities• Ebsilon Solar – Proprietary

thermodynamic design software• Solar simulator - with Trax• Owners Engineer NTPC Anta• Training on Solar – With IITJ

• Identification of specific projects

WindWind

• 50 MW plant at Arenales

SolarSolar

Steag Projects

STEAG holds a strong position in the renewable energy market

PlantsPlantsInstalled capacity

Installed capacity

• since 2002• #3 in Germany

• since 2007• First own biogas plant

commissioned

• since1908• #1 in Germany



Total

Sites of Evonik New Energies GmbH

SubsidiariesBiomass*Biomass*

BiogasBiogas

Mine gasMine gas

ContractingContracting

GeothermalGeothermal

66

177

77

--

319

154

139

905

71

1,271

MWel MWth

13

108

100

2

223

Steag has a 26% stake Planned start date – Sept. 2013 O&M shall be done by Steag Technical concept comparable to

Andasol 3 Capacity of the plant: 49.9 MW Wet cooling tower implemented Solar field with 156 Loops

Parabolic Collectors Thermal Storage (salt) for up to

7h of full load operation Gross electricity production:

about 170 GWhel p.a. Planned operation period: 40 Yrs

The implemented technical concept is state of the art for CSP plants in Spain

Arenales 50 MW plant in Spain







• CCPP Capacity 419.38 MW (Design)

• 3x 88.70MW GT13D2 -ABB Gas Turbine

• 1x 153.28 MW Alstom- Steam Turbine

• 3 HRSG WAAGNER-BIRO, Forced circulation / Vertical

arrangement

• 220 kV Switchyard

• Year of commissioning:1989

EXISTING CONFIGURATION of NTPC’s ANTA CCPP

SOLAR FIELD LAYOUT WITH CCPP INTEGRATION

15 MW Capacity, 132 Collectors, Solar Field Size Optimized Based On Margin Available In Existing Anta CCPP

LIMITING BOUNDARY CONDITIONS

1. Steam Turbine maximum main steam flow limited to 488 tph to HP-Turbine and 601 tph to LP-Turbine according to heat balance diagram “peak load”.

2. Condenser main steam flow limited to 601 tph according to heat balance diagram.

3. ST generator transformer rated at 195MVA

INTEGRATION OPTIONS

1. Solar Steam integration in to HP Drum of each of 3 existing HRSGs

2. Solar Steam integration in to HP Super Heater of each of 3 existing HRSGs

3. Solar Steam @ 3700 C integration in to HP Main Steam Header (4850 C) before Steam Turbine

4. Solar Steam with separately fired Super Heater and Integrating in to HP Main Steam Header before Steam Turbine

5. New BPST integrated at existing LP main steam header

6. New Condensing Steam Turbine Integrated at existing condenser.

7. Standalone Power Plant.

7.1 Standalone Power Plant generation at 6.6kV level.

7.2 Standalone Power Plant generation at 15.75kV level.

7.3 Standalone Power Plant generation at 11kV/220kV level.

7.3 A Standalone Power Plant 18MW capacity generation at 11kV/220kV level.

7.3 B Standalone Power Plant 21MW capacity generation at 11kV/220kV level.

Exploring different options by modeling on EBSILON software

● User friendliness by intuitive handling (100 % Windows compliant)● Graphical objects for components and pipes (component library)● Complete observance of physical laws ● No restrictions regarding variety and size of the model ● Easy expandability of existing models

● Design and part load calculation possible

● Extension by self-defined components (Macros) possible● Large number of fluids considered (water/steam, air, fluegas, coals, oils, gases,

refrigerants, seawater, mixtures, self-defined fluids)● Fast diagnosis of topology- and specification errors ● Multilingual User Interface (German, English, French, Spanish, Turkish, Chinese)● different Unit Systems (SI, BTU + other units)

EBSILON®Professional - Salient features

A tool for the simulation of all kinds of thermal power plants (fossile, nuclear, CSP, CHP, ORC, refrigeration)

11

Sun

12

• Provides methods to calculate the sun position and incident angles on single axis tracking surfaces

• Flexibility to either use the calculated values from geographical data and time or to directly enter any specific value.

• It is possible to change irradiance data and ambient data globally for all components

• Possible to override globally specified values and enter unique value for any specified component.

Sun

13

Line-focussing solar collector

• This component represents a single line-focussing solar collector which can be of parabolic trough or linear Fresnel type.

• The underlying models calculate the energy balance from direct solar irradiation to usable heat in the heat transfer fluid / water

• For efficiency data, the user has the possibility to:

o define the coefficients in standard formulations,

o to use an adaptation function or

o to define data tables for interpolation 14

Calculation of heat added to the fluid

M1*(H2-H1) = QEFF

QEFF = QSOLAR - QLOSS

QSOLAR = DNI * ANET * FOPT_0 * KIA * FOCUS * ETASHAD * ETAENDL * ETASPILL * ETA_CLEAN

DNI Direct normal irradiance in W/m**2

ANET Net aperture area ANET=LENGTH*AWIDTH*NRATIO

FOPT_0 Peak optical efficiency (parameter FOPT0)

KIA Incident angle correction (cosine losses already included)

FOCUS Focus state of the collector

ETASHAD Factor to include shading losses

ETAENDL Factor to correct end loss effects determined from model

ETASPILL Factor to include optical losses due to wind impact

ETA_CLEAN Factor to correct for actual mirror cleanliness ETA_CLEAN=CLEANI

15

End loss and End Gain

End loss

End lossEnd Gain

16

Incident angle correction

• At non-perpendicular incident of the sun additional losses due to shading of collector structure elements, a longer optical path of the reflected sun rays and angle-dependent optical properties of mirrors and absorber tube occur.

• These optical effects are summarized in the incident angle correction KIA which also includes the cosine losses.

I

IH

B

COS I = B-H

17

Heat loss parameters and calculations

QLOSSA0 Coefficient for standard formulation (constant Term in dT)

QLOSSA1 Coefficient for standard formulation (linear Term in dT)

QLOSSA2 Coefficient for standard formulation (^2 Term in dT)



QLOSSB0 Coefficient for standard formulation (const. Term in dT)

QLOSSB1 Coefficient for standard formulation (lin. Term in dT)

QLOSSB2 Coefficient for standard formulation (^2 Term in dT)

EQLOSS for FQLOSS=1 adaptation function for receiver heat losses. Result: [W/m]

qloss = QLOSSA0 + QLOSSA1*dT + QLOSSA2*dT**2 + QLOSSA3*dT**3 + QLOSSA2*dT**4 + QLOSSB0 * RDNI * r_opt + QLOSSB1 * RDNI * r_opt *dT + QLOSSB2 * RDNI * r_opt *dT**2

where r_opt = KIA * FOCUS * ETASHAD * ETAENDL * ETASPILL * ETA_CLEAN18

Distributing Header

• Intended to model a header that equally distributes a fluid stream on a number of branches.

• In addition to mass it offers a heat and momentum balance too

• Only one "representative branch" is modeled via connection point 2

• The branching points along the header may have different enthalpies and pressures due to heat and pressure loss effects 19

Collecting Header

• Used in conjunction with distributing header to model the collection from number of branches having equal mass flows into one header.

• The user has to specify the number of junction points along the header

• Some of the collecting header parameters are normally identical to the ones of the distributing header therefore both can be synchronized

20

Model created on Ebsilon for evaluatingdifferent integration options

21

OPTION -1 SOLAR STEAM INTEGRATION IN TO HP DRUM OF EACH OF 3 EXISTING HRSGS

BRIEF DESCRIPTION • Up to approx. 80 TPH solar steam is equally injected into

the HP Drums of all 3 HRSGs

HP DRUM

OPTION -1 SOLAR STEAM INTEGRATION IN TO HP DRUM OF EACH OF 3 EXISTING HRSGS

IMPLICATIONS– All the 3 HRSG’s will require

major modification

– Steam flow in HRSG will increase substantially

– Increased steam flow will have to pass into the HP Turbine and then on into LP Turbine.

– Existing ST Generator transformer has 195 MVA rating. Margin for additional Solar power evacuation at 0.8 power factor is very little.

RISKS– Increased steam flow in HRSG

could disturb HRSG dynamics.

– Max generation would be limited by max steam flow permitted in Steam Turbine.

– It would be difficult to determine contribution of solar steam generation for tariff purposes

– Consultation with OEM will be necessary. Even if feasibility is technically established, risk of OEM Guarantees remains owing to age (20Years) of the units.

– Solar Power can be evacuated keeping the power factor close to unity. This can impose limitation on flexibility in operating the plant

OPTION -2SOLAR STEAM INTEGRATION IN TO HP SUPER HEATER OF EACH OF 3 EXISTING HRSGS

BRIEF DESCRIPTION

Up to approx. 80 TPH solar steam at 70 bar pressure, 3700 C is equally injected into Super Heater inlet Headers of all 3 HRSGs

OPTION -2SOLAR STEAM INTEGRATION IN TO HP SUPER HEATER OF EACH OF 3 EXISTING HRSGS

IMPLICATIONS– All the 3 HRSG’s will require

major modification

– Steam flow in the HRSG will be substantially increased.

– This increased steam will have to pass into the HP Turbine and then on into LP Turbine.

– Existing ST Generator transformer having 195 MVA rating. Margin for additional Solar power evacuation at 0.8 power factor is very little.

RISKS– Increased steam flow in HRSG

could disturb HRSG dynamics.– Max generation would be

limited by max steam flow permitted in Steam Turbine.

– It would be difficult to determine contribution of solar steam generation for tariff purposes

– Consultation with OEM will be necessary. Even if feasibility is technically established, risk of Guarantees remains owing to age (20Years) of the units.

– Solar Power can be evacuated keeping the power factor close to unity. This can impose limitation on flexibility in operating the plant.

OPTION -3SOLAR STEAM @ 3700 C INTEGRATION IN TO HP MAIN STEAM HEADER (4850 C) BEFORE STEAM TURBINE

BRIEF DESCRIPTION

Up to approx. 80 TPH Solar steam at 70 bar pressure, 3700 C is mixed in the HP Main Steam Header ( 4850 C) before steam turbine with suitable mixing arrangement.

IMPLICATIONS

– Large Temperature difference between Solar steam and HP Steam from HRSG.


RISKS

– Max generation would be limited by max steam flow permitted in Steam Turbine.

– Consultation with OEM will be necessary. Even if feasibility is technically established, risk of Guarantees remains owing to age (20Years) of the units

– It would be difficult to determine contribution of solar steam generation for tariff purposes.


OPTION -3SOLAR STEAM @ 3700 C INTEGRATION IN TO HP MAIN STEAM HEADER (4850 C) BEFORE STEAM TURBINE

BRIEF DESCRIPTION

Up to approx. 80 TPH Solar steam at 70 bar, 3700 C is superheated in a separately fired super heater and solar steam temperature raised up to 4850 C matching the Main Steam HP Header parameters before introducing into steam turbine.

OPTION -4SOLAR STEAM WITH SEPARATELY FIRED SUPER HEATER AND INTEGRATING IN TO HP MAIN STEAM HEADER BEFORE STEAM TURBINE

IMPLICATIONS– Separate fired

superheater would need supplementary heating by gas-fired burners. This would increase fossil fuel consumption at low efficiency.


RISKS– Additional fossil fuel

consumption will be unacceptable.


– It would be more difficult to determine contribution of solar steam generation for tariff purposes compared to options 1-3

OPTION -4SOLAR STEAM WITH SEPARATELY FIRED SUPER HEATER AND INTEGRATING IN TO HP MAIN STEAM HEADER BEFORE STEAM TURBINE

OPTION-5NEW BPST INTEGRATED AT EXISTING LP MAIN STEAM HEADER

BRIEF DESCRIPTION

Up to approx. 80 TPH Solar steam at 30 bar,3700 C is introduced in to New Back Pressure Steam Turbine(BPST). The BPST exhaust will be connected to existing plant LP Main steam header before LP turbine. BPST designed in such a way that the exhaust steam parameters will be matched with the LP Main Steam Header Parameters .

BPST generator will use the existing Steam Turbine Generator Transformer for power evacuation.

IMPLICATIONS

– The BPT exhaust steam which will be mixed with LP steam entering the LPT is limited by the steam flow capacity of the LPT. Balance of the BPT exhaust steam will have to be dumped into condenser.

– Large quantity of BPT exhaust steam needs to be dumped. Total generation by BPT is not very high.


RISKS

– Max generation would be limited by max steam flow permitted in LP Turbine.


OPTION-5NEW BPST INTEGRATED AT EXISTING LP MAIN STEAM HEADER

OPTION-6NEW CONDENSING STEAM TURBINE INTEGRATED AT EXISTING CONDENSER

BRIEF DESCRIPTION

Up to approx. 80 TPH Solar steam at 30 bar, 3700 C is introduced in to a New Condensing Steam Turbine (CST). The CST exhaust steam will be dumped in to existing Condenser.

CST generator will use the existing Steam Turbine Generator Transformer for power evacuation

IMPLICATIONS

– The CST exhaust steam, which can be exhausted to condenser, is limited by the steam flow capacity of the condenser.

– Max generation would be limited by max steam flow permitted in condenser.


RISKS

– Installing a new CST will require new pedestal close to the existing STG. This might be a serious problem. Also it may not feasible to inject CST steam into the condenser via a new opening in condenser neck.


– Very small cost advantage, hardly technical advantages from this integration concept

OPTION-6NEW CONDENSING STEAM TURBINE INTEGRATED AT EXISTING CONDENSER

OPTION -7 STAND-ALONE POWER PLANT

BRIEF DESCRIPTION

This option is for a completely independent power plant with steam from solar system. The new equipment will include Steam Turbine Generator, Condenser, Condensate and feed water pumps, deaerator, feed water heater, turbine auxiliaries, Condenser Cooling Water system.

Following possible options are considered:

• Generation at 6.6 kV, feeding into 6.6 kV bus• Generation at 15.75 kV, feeding into primary of existing

Generator Transformer• Generation at 11 kV, feeding into new 11/ 220 kV Generator

Transformer and cabled into switchyard. 3 possible Solar Generation capacities are considered.







• Existing generation data (for 1 year) was studied to establish the spare capacity of turbine. About 5 MW found.

• Design and capacity of other components (condenser, generator, headers etc.) was examined for taking this extra load if provided – Found OK

• Site surveyed and three plots identified. All of them were rectangular areas with longer side in almost NS direction. Land identification is a challenge in retrofits.

• Modeling was done on Ebsilon to evaluate the potential for integrating the proposed solar fields with the existing plant. This would establish the solar field size with reference to the DNI and plots available.

• Modeling was also done for various injection points of steam and extraction points for water and the cumulative power production was calculated in each case for TMY.

5 MW proposed Solar integration at a Cement Cement – Steps & Methodology

Existing Setup

• Heat from three kilns.

• Each kiln contributes flue gasses from two areas. Pre-heater (low temp) and Kiln Cooler (high temperature)

• So six boilers. Three HP boilers – HP header. Three LP boilers - LP header

• Dual injection turbine.

• HP injection at 19 bar and 370 degrees

• LP injection at 4.5 bar and 179 degree

Modeling option 1 – Water tapping from BFP inlet

Modeling option 2 – Water tapping GSC outlet







•The plants are owned by Steag•Studies have been done by Steag – Germany

o 2 x 660 MW coal-fired power plant Sugözü in Turkeyo 165 MW coal-fired power plant Termopaipa in Colombia o Coal-fired power plants in Brazil

Hybridization studies by Steag Germany

Options for topping in Steag’s 2X660 MW plant at Turkey

Bypasses the original heaters.Similar concept proposed by NTPC.







Exterior View of the 12MWe Combined Solar Biomass Desalination Plant from the Desalination

Side including Air Cooled Condenser

Exterior View of the 12MWe Combined Solar Biomass Desalination Plant from the Solar Field side

WHAT IS SPECIAL ABOUT THIS PROJECT

SOLAR THERMAL

FIELD10% of Heat

Desalination unit

Solar Biomass Hybrid Power Plant with Desal WTP

BIOMASS FLOW RATE = 12.8 TPHJULI FLORA up to 100%COTTON STALK 20%

12MW

WATER PRODUCTION OF 160 M3/DAY DM WATER QUALITY

Presentation on CSP integration with conventional power plants Solar market in India 2013 7 th – 8 th May 2013, New Delhi Dr. J.T.Verghese – Managing Director.

Documents

mw plant

solar steam integration

mw capacity

services hybridization

solar field layout

solar field size

ntpc plant

discussion slide