Seminar PDF

Flexibility optimization
of new and existing

fossil fired power plants
Indo-German Energy Forum
EEC Seminar, Ahmedabad, India, February 6th , 2020
Axel Meschgbiz, RWE Technology International
RWE | flexibility | new built plants | existing plants | summary
Content
> Who is RWE?
> What does Flexibility mean?
> Flexibility for new built Plants
> Flexibility of existing Plants
> Fuel Flexibility
> Summary
RWE Technology International 12/02/2020 PAGE 2

Who is RWE?
Largest Generator in Germany / Major assets in NL/UK.
Pro forma combined electricity generation capacity1
2,7; Fuelled by RWE’s own

Gas Renewables Other 6% lignite mines:
10,3;
Lignite Hard coal Nuclear 23%
9,3; - Hambach
20% - Garzweiler
- Inden
46 GW
6,5; Total production
14% 86 Mio t/y (2018)
14,1; 2,8;
6%
31%
1 RWE stand-alone plus E.ON’s and innogy’s renewables businesses.

.
(as of 1 January 2019)

RWE Technology International (RWE-TI):

Engineering. Consulting. Utility roots.
Our advice is based on the
experience as owner and
operator of world-class assets.
We enable clients to advance

efficiency, safety and
sustainability of their businesses.
Our services include: thermal

power, utility-scale renewables and
open-cast mining.
50+ 100+ 120+ 200+ 1000+

years established as countries we have years of heritage as highly qualified engineers successful projects
engineering consultant experience in pioneers of power industry and consultants performed world-wide

RWETI: Our core services

Mining
Mining is our heritage. We have over 50 years of unique
continuous mining tradition and conveyer belt know-how that
customers all over the world are taking advantage of.
Thermal Generation
We have advised on over 300 thermal projects around the
world, helping customers to increase efficiency, reliability and
manage costs in projects and operations.
Renewables
We offer technical advisory services and investment support
for renewables, covering a variety of technologies including
solar, wind, hydro, biofuels and energy storage.

What does flexibility mean?

High flexibility can be described as follows:
Dynamic flexibility Operational flexibility
> High operational gradient (load > High number of start ups and load
change speeds) cycles at reduced lifetime
consumption
> Short start-up time and short
minimum downtime > High efficiency at lowest possible
minimum load
> Lowest possible minimum load
and options to temporarily > Uniform, high efficiency curve
maximize the load across the load
> Fuel flexibility
RWE’s philosophy regarding flexibility:

 Create value by combining technical solutions, process
improvements, culture change and market focus!

RWE made a lot of effort to increase flexibility and

efficiency of its plants in the last decades – Example Lignite:
Next Project:
2x 550 MW
Pre-dried lignite
CFBC Units
?
COD:
Coal:

Average Efficiency gain along the Power Plant

Process
1957 1976 Today
RWE Technology International PAGE 8

Design specifications of new power plants

Example: 800 MWe Power plant Westfalen, Germany
Operational characteristics
(Hard Coal, 800 MW) Operation Mode yearly 40 years
> Base and medium load

Cold Starts 6 240
> Plant runs through in times of
low demand Warm Starts 42 1,680
> Minimum load 25 - 30%, 7,500 Hot Starts 84 3,360

operation hours per year Load Cycles 1,200 48,000
 Flexibility requirements are assessed and taken into

account during the design stage of the plant.

New advanced materials allow increase in

flexibility or efficiency
Efficiency development of lignite-fired plants
Nickel-base High efficiency

55 alloys Increase in steam
(up to 700°C) parameters for
50 new build plants
(700ºC power plant)
45
Efficiency [%]
High flexibility
40 Constant steam
parameters in
35 existing and new
State of the art plants
30 (600ºC live steam
1970 1990 2010 2030 temperature)
Commissioning
 Use of nickel-base alloys depends on operating conditions

of future power plants.

Short minimum downtime

Lifetime consumption consideration
> After command “fire off" Renewables vs. Conventional PP
measures must be carried out
to bring the unit fast back into
the "Ready" operating state.
Hereby, the condition of the
unit must be considered. Power by Renewables
Ideal respond fossil PP
> Time leader in coal firing is the Real respond PP
pre-ventilation due to security.
> Gentle cooling of the steam in todays
market
generator before air purging,
which increases the life time With low With high
Minimum downtime Life Time Life Time
but is time-consuming. This reduction reduction
measure avoids the hard coal / lignite < 240 min min. 30 min
temperature stresses.
 Lifetime consumption is considered in the design
and in the operation of our plants.
I&C optimization makes modern power plants

even faster
Coal-fired power plants
(e.g. 600 MW unit D, Neurath) 700
600
> Reduction in minimum load:
500
20%-points
Load in MW
400
> Increase in load change rate: 300
5 MW/min  15 MW/min 200
100
> Secondary reserve capability: old/design proofed feasible
0
±70 MW in 15 min
Load ±70 MW in 15 min
Time

Start up optimization at a 600 MW unit

before optimization > Question limitations and boundary
values
Pre-Ventilation > Parallelize processes
> Minimize waiting times
Oil/Coal
> Assess of components were the
Load maintenance is crucial and ensure
good condition of these
components
after optimization > Faster startups …
… without increased lifetime consumption
Pre- Load ... without reduced plant safety
Ventilation
 Key to success:
Oil/Coal Combination of expertise in
process technology and I&C
optimization.

Start up optimization steps at a 600 MW unit

Starting Point (cold start in year 2010)


First optimisation stage (cold ctart in year 2011)


Second optimisation stage (cold start in year 2013)

Market-oriented control
Forecasting of available performance
Closed loop process that combines RWE‘s expertise as operator and trader
power plant forecast and control

dispatch
diagnosis system of capacity
distributed control load control

unit
system (DCS) system
> Technically established forecast increases transparency and forecast

accuracy (day ahead and intraday)
> Market-oriented control of the load capacity
> More accurate following of schedule by units
> Substantial simplification of daily business (communication dispatch
and power plant)
RWE Technology International 12.02.2020 PAGE 17

Application: Maximal load optimization

Control and forecasting of available performance
Prognosis tool based on data from a process quality optimization system
> Fully automated market-oriented provision of power (incl. options such as preheater operation,
etc.)
> Consideration of the current condition of the unit and external influences


etc.)


etc.)

Predicting dynamic minimal load

Example: Combined heat and power plant (CHP)
Big Data based prognosis tool

(1)
1. Forecast of heat demand of different
consumers (must run plant)
2. Minimal load prognosis based on
heat demand forecast
3. Processed information to be utilized
by the dispatcher
(3) (2)
 BENEFITS
> Minimize losses due to
must run conditions
> Avoid start of backup heat supply
unit by minimizing minimal load

Fuel Flexibility
in Power
Plants

Quality Requirements on Coals

From the view of fuel purchaser and power plant operator
Fuel Purchaser Power Plant Operator

• Low-price purchase • Handling and storage
• Undisturbed transport • Milling and firing
• Universal and low-priced coal input • Ignition stability, flame stability
• Few restrictions relating to coal quality • Compliance with all limit values of
emissions
• By-products marketing
• Avoiding mid-term & long-term damages
 “Price Thinking”  “Costs-Thinking”

Fuel Properties– complete analysis required

> Proximate analysis
– H2O, ash and volatile matter (VM) Coal Type Moisture
( ar %)
Heating
Value
Volatiles
( daf %)
(af kJ/kg)
> Calorific value
– Lower calorific value, higher calorific value
> Elementary analysis
– C, H, N, O, S, Cl, F
> Ash analysis of macro-elements (XRF)
– SiO2, Al2O3, TiO2, Fe2O3, CaO, MgO, K2O,
Na2O, P2O5, SO3
> Ash fusion trajectory in oxidizing and
reducing atmosphere
– Initial deformation temperature (IDT)
– Softening temperature (ST)
– Hemispherical temperature (HT)
– Fluid temperature (FT)
– Grindability (HGI, PMI)
* ar = as received **af = ash free ***daf = dry and ash free
 Complete analysis gives the whole picture

of the combustion behaviour of a fuel
Fuel Handling
Preventing self ignition and fire
Prevention
Fire at Sub-Bituminous Stock pile
 RWE has installed Online Temperature Monitoring for all

Stock Piles
 Fuel Management System (FMS) controls detail storage
and Coal Properties Data (incl. Ash Composition)

Influence of Coal Impurities

Fouling and Slagging is a major Issue (Ash Impurities)
Bündel-
hen
heizfläc Fouling Zone
mmer
Brennka
iz fl äc hen
he
Eco-
hen
heizfläc
Zur
um- REA
Feuerra
ende
Sintering Zone
Feuer-
raum
zw. Luvo E-Filter-
2. Zug- b zug
Leerzug
- A cheab
s
Brenner- zug
Ascheab
gürtel
Economiser
nter
heruby
Blockage Slagging Zone
bis soot blowing
he- 600 °C 170 °C
Nassasc 1150 °
C bis gaswe
g
abzug C 400 °C Rauch
1300 ° bis
egen
de n
bis 600 °C rlauf g
1400 °
C per aturve
er Tem
atisch
schem Ash Extraction
blockage

Influence on the Combustion

Furnace Temperature Distribution
 The Furnace Exit Gas Temperature (FEGT) must be kept

bellow the Ash Softening Temperature
Retrofit based of CFD Calculations

Example: Retrofit of a 600 MWe Lignite Unit
Before retrofit After Burner retrofit
FEGT > Ash Softening Point = FEGT << Ash Softening Point = 1100°C
1100°C
Heating Surface
OFA Level 2
OFA Level 1
Burner Level 1
Burner Level 2

Influence on Power Plant Components

Example: ESP Corrosion in a 700 MWe Hard Coal Plant, South China
 Due to combustion of particular imported coals the

flue gas temp. is critically close to the acid dew
point and in some periods bellow it
R&D activities related to flexibility increase

> New materials for thin-walled flexible
components
> New measurement methods and IT
based monitoring to assess the life
consumption to avoid damage of
highly stressed components
> Big Data for predictive maintenance,
monitoring components and forecasting of
market data and power plant operation
> Temporary electricity storage, when the
produced electricity
from conventional power plants is not
required
> New combustion systems for lignite
based dry lignite in order to increase the
flexibility
> Fuel Flexibility by optimization of coal
online analysis and coal management
system

Future design and optimization priorities
Investment cost

Design Process
Lifetime operation The prioritization efficiency
scheme
is based on the
value of flexibility!
flexibility

Thank you very muchAny
for Questions ?
your attention
Contact
Axel Meschgbiz
E [email protected]
T +49 201 12 22507
M +49-162-2508213
Ernestinenstraße 60
45141 Essen
Germany

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Flexibility optimization

of new and existing

> Who is RWE?

> What does Flexibility mean?

> Flexibility for new built Plants

> Flexibility of existing Plants

> Fuel Flexibility

RWE Technology International 12/02/2020 PAGE 2

2,7; Fuelled by RWE’s own

1 RWE stand-alone plus E.ON’s and innogy’s renewables businesses.

RWE Technology International 12/02/2020 PAGE 3

RWE Technology International (RWE-TI):

We enable clients to advance

Our services include: thermal

50+ 100+ 120+ 200+ 1000+

RWE Technology International 12/02/2020 PAGE 4

RWETI: Our core services

RWE Technology International 12/02/2020 PAGE 5

What does flexibility mean?

RWE’s philosophy regarding flexibility:

RWE Technology International 12/02/2020 PAGE 6

RWE made a lot of effort to increase flexibility and

RWE Technology International 12/02/2020 PAGE 7

Average Efficiency gain along the Power Plant

1957 1976 Today

RWE Technology International PAGE 8

Design specifications of new power plants

> Base and medium load

> Minimum load 25 - 30%, 7,500 Hot Starts 84 3,360

 Flexibility requirements are assessed and taken into

RWE Technology International 12/02/2020 PAGE 9

New advanced materials allow increase in

Nickel-base High efficiency

 Use of nickel-base alloys depends on operating conditions

RWE Technology International 12/02/2020 PAGE 10

Short minimum downtime

I&C optimization makes modern power plants

Load ±70 MW in 15 min

RWE Technology International 12/02/2020 PAGE 12

Start up optimization at a 600 MW unit

RWE Technology International 12/02/2020 PAGE 13

Start up optimization steps at a 600 MW unit

RWE Technology International PAGE 14

Start up optimization steps at a 600 MW unit

RWE Technology International PAGE 15

Start up optimization steps at a 600 MW unit

RWE Technology International PAGE 16

power plant forecast and control

distributed control load control

> Technically established forecast increases transparency and forecast

RWE Technology International 12.02.2020 PAGE 17

Application: Maximal load optimization

Prognosis tool based on data from a process quality optimization system

RWE Technology International 12.02.2020 PAGE 18

Application: Maximal load optimization

Prognosis tool based on data from a process quality optimization system

RWE Technology International 12.02.2020 PAGE 19

Application: Maximal load optimization

Prognosis tool based on data from a process quality optimization system