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

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

1 Presentation on CSP integration with conventional power plants Solar market in India th – 8th May 2013, New Delhi Dr. J.T.Verghese – Managing Director Steag Energy Services India Pvt. Ltd.

2 Topics for discussion 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

3 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

4 STEAG holds a strong position in the renewable energy market
Installed capacity Plants Sites of Evonik New Energies GmbH Subsidiaries Biomass* 66 154 13 MWel MWth since 2002 #3 in Germany Biogas since 2007 First own biogas plant commissioned Mine gas 177 139 108 Identification of specific projects Wind 50 MW plant at Arenales Solar Steag Projects since1908 #1 in Germany Geothermal -- 71 2 since 1994 #1 in Germany Contracting 77 905 100 since 1961 #2 in Germany Total 319 1,271 223

5 Arenales 50 MW plant in Spain
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

6 Topics for discussion 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

7 EXISTING CONFIGURATION of NTPC’s ANTA CCPP
CCPP Capacity  MW (Design) 3x 88.70MW GT13D2 -ABB Gas Turbine 1x MW Alstom- Steam Turbine 3 HRSG WAAGNER-BIRO, Forced circulation / Vertical arrangement 220 kV Switchyard Year of commissioning:1989 7

8 SOLAR FIELD LAYOUT WITH CCPP INTEGRATION
15 MW Capacity, 132 Collectors, Solar Field Size Optimized Based On Margin Available In Existing Anta CCPP

9 LIMITING BOUNDARY CONDITIONS
Steam Turbine maximum main steam flow limited to tph to HP-Turbine and 601 tph to LP-Turbine according to heat balance diagram “peak load”. Condenser main steam flow limited to 601 tph according to heat balance diagram. ST generator transformer rated at 195MVA

10 INTEGRATION OPTIONS Solar Steam integration in to HP Drum of each of 3 existing HRSGs Solar Steam integration in to HP Super Heater of each of 3 existing HRSGs Solar 3700 C integration in to HP Main Steam Header (4850 C) before Steam Turbine Solar Steam with separately fired Super Heater and Integrating in to HP Main Steam Header before Steam Turbine New BPST integrated at existing LP main steam header New Condensing Steam Turbine Integrated at existing condenser. 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. 10

11 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)

12 Sun

13 Sun 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.

14 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: define the coefficients in standard formulations, to use an adaptation function or to define data tables for interpolation

15 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

16 End loss and End Gain End loss End loss End Gain

17 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. B - H COS I = B I I H

18 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) QLOSSA3 Coefficient for standard formulation (^3 Term in dT) QLOSSA4 Coefficient for standard formulation (^4 Term in dT) QLOSSB0 Coefficient for standard formulation (const. Term in dT) QLOSSB1 Coefficient for standard formulation (lin. Term in dT) QLOSSB2 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_CLEAN

19 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

20 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

21 Model created on Ebsilon for evaluating different integration options

22 OPTION -1 BRIEF DESCRIPTION
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 22

23 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 23

24 OPTION -2 BRIEF DESCRIPTION
SOLAR 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 24

25 OPTION -2 SOLAR 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. 25

26 BRIEF DESCRIPTION OPTION -3
SOLAR 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. 26

27 OPTION -3 SOLAR 3700 C INTEGRATION IN TO HP MAIN STEAM HEADER (4850 C) BEFORE STEAM TURBINE IMPLICATIONS Large Temperature difference between Solar steam and HP Steam from HRSG. Existing ST Generator transformer having 195 MVA rating. Margin for additional Solar power evacuation at 0.8 power factor is very little. 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. Solar Power can be evacuated keeping the power factor close to unity. This can impose limitation on flexibility in operating the plant. 27

28 BRIEF DESCRIPTION OPTION -4
SOLAR STEAM WITH SEPARATELY FIRED SUPER HEATER AND INTEGRATING IN TO HP MAIN STEAM HEADER 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. 28

29 OPTION -4 SOLAR 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. Existing ST Generator transformer having 195 MVA rating. Margin for additional Solar power evacuation at 0.8 power factor is very little. RISKS Additional fossil fuel consumption will be unacceptable. Solar Power can be evacuated keeping the power factor close to unity. This can impose limitation on flexibility in operating the plant. It would be more difficult to determine contribution of solar steam generation for tariff purposes compared to options 1-3 29

30 OPTION-5 BRIEF DESCRIPTION
NEW 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. 30

31 OPTION-5 NEW BPST INTEGRATED AT EXISTING LP MAIN STEAM HEADER RISKS
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. Existing ST Generator transformer having 195 MVA rating. Margin for additional Solar power evacuation at 0.8 power factor is very little. RISKS Max generation would be limited by max steam flow permitted in LP Turbine. Solar Power can be evacuated keeping the power factor close to unity. This can impose limitation on flexibility in operating the plant. 31

32 OPTION-6 BRIEF DESCRIPTION
NEW 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 32

33 OPTION-6 NEW CONDENSING STEAM TURBINE INTEGRATED AT EXISTING CONDENSER
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. Existing ST Generator transformer having 195 MVA rating. Margin for additional Solar power evacuation at 0.8 power factor is very little. 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. Solar Power can be evacuated keeping the power factor close to unity. This can impose limitation on flexibility in operating the plant. Very small cost advantage, hardly technical advantages from this integration concept 33

34 OPTION -7 BRIEF DESCRIPTION STAND-ALONE POWER PLANT
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 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. 34

35 Topics for discussion 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

36 5 MW proposed Solar integration at a Cement Cement – Steps & Methodology
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.

37 Dual injection turbine. HP injection at 19 bar and 370 degrees
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

38 Modeling option 1 – Water tapping from BFP inlet

39 Modeling option 2 – Water tapping GSC outlet

40 Topics for discussion 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

41 Hybridization studies by Steag Germany
The plants are owned by Steag Studies have been done by Steag – Germany 2 x 660 MW coal-fired power plant Sugözü in Turkey 165 MW coal-fired power plant Termopaipa in Colombia Coal-fired power plants in Brazil

42 Options for topping in Steag’s 2X660 MW plant at Turkey
Bypasses the original heaters. Similar concept proposed by NTPC.

43 Topics for discussion 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

44 Exterior View of the 12MWe Combined Solar Biomass Desalination Plant from the Desalination Side including Air Cooled Condenser

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

46 WHAT IS SPECIAL ABOUT THIS PROJECT
Solar Biomass Hybrid Power Plant with Desal WTP SOLAR THERMAL FIELD 10% of Heat 12MW BIOMASS FLOW RATE = 12.8 TPH JULI FLORA up to 100% COTTON STALK 20% Desalination unit WATER PRODUCTION OF 160 M3/DAY DM WATER QUALITY

47


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